TECHNICAL FIELD
[0001] An operator control system is provided for a materials handling vehicle, wherein
one or more components of the operator control system is adjustable.
BACKGROUND ART
[0002] Known materials handling vehicles include a power unit, a mast assembly and an operator
compartment. The mast assembly may include a plurality of mast weldments, wherein
a first mast weldment may be fixed to the power unit and one or more other mast weldments
may be supported for telescoping movement. An operator compartment in the materials
handling vehicle may be supported for vertical movement on the mast assembly for positioning
an operator to retrieve items from shelves at elevated locations.
DISCLOSURE OF INVENTION
[0003] In accordance with a first aspect of the disclosure, an operator control system for
a materials handling vehicle is provided, in which the materials handling vehicle
comprises an operator station having a floorboard and a support structure and the
operator control system comprises: an operator control assembly, a fixture structure
coupled to the support structure to selectively support the operator control assembly
in a plurality of angular orientations relative to the support structure, and a vertical
adjustment assembly coupled to the operator control assembly to selectively support
the operator control assembly at a plurality of vertical positions relative to the
floorboard.
[0004] The fixture structure may comprise a mounting plate with one or more first openings
and one more second openings and a plurality of fasteners that couple a housing of
the operator control assembly to the support structure. The operator control assembly
may be mounted at a first angular orientation relative to the support structure when
the fasteners are received in the one or more first openings of the mounting plate
and a second angular orientation relative to the support structure when the fasteners
are received in the one or more second openings, in which the second angular orientation
may be different from the first angular orientation. The operator control assembly
may be rotated about an axis generally parallel to a longitudinal axis of the materials
handling vehicle when moved from the first angular orientation to a second angular
orientation.
[0005] The support structure may comprise a fixed housing portion and a movable housing
portion, in which the movable housing portion may be coupled to and movable with the
operator control assembly and may be positioned to telescope over the fixed housing
portion.
[0006] The operator control assembly may be continuously movable in a vertical direction
between a first vertical position and a second vertical position.
[0007] The vertical adjustment assembly may comprise: a mounting plate attached to a support
wall of the materials handling vehicle, a rail member attached to the mounting plate,
a carriage assembly movably coupled to the rail member and coupled to the fixture
structure, and a locking gas spring coupled to the fixture structure and the mounting
plate to control the vertical position of the operator control assembly.
[0008] In accordance with a second aspect of the present disclosure, an operator control
system for a materials handling vehicle is provided, in which the materials handling
vehicle comprises an operator station having a floorboard, a first support structure,
and a second support structure spaced apart from the first support structure in a
lateral direction and the operator control system comprises: a first operator control
assembly, a first fixture structure coupled to the first support structure to selectively
support the first operator control assembly in a plurality of angular orientations
relative to the first support structure, and a first vertical adjustment assembly
coupled to the first operator control assembly to selectively support the first operator
control assembly at a plurality of vertical positions relative to the floorboard;
and a second operator control assembly, a second fixture structure coupled to the
second support structure to selectively support the second operator control assembly
in a plurality of angular orientations relative to the second support structure, and
a second vertical adjustment assembly coupled to the second operator control assembly
to selectively support the second operator control assembly at a plurality of vertical
positions relative to the floorboard.
[0009] The first fixture structure may comprise a first mounting plate with one or more
first openings and one more second openings and a first plurality of fasteners that
couple a first housing of the first operator control assembly to the first support
structure. The first operator control assembly may be mounted at a first angular orientation
relative to the first support structure when the first plurality of fasteners are
received in the one or more first openings and a second angular orientation relative
to the first support structure when the first plurality of fasteners are received
in the one or more second openings, in which the second angular orientation may be
different from the first angular orientation. The second fixture structure may comprise
a second mounting plate with one or more third openings and one or more fourth openings
and a second plurality of fasteners that couple a second housing of the second operator
control assembly to the second support structure. The second operator control assembly
may be mounted at a third angular orientation relative to the second support structure
when the second plurality of fasteners are received in the one or more third openings
and a fourth angular orientation relative to the second support structure when the
second plurality of fasteners are received in the one or more fourth openings, in
which the fourth angular orientation may be different from the third angular orientation.
[0010] The first operator control assembly may be rotated about a first axis generally parallel
to a longitudinal axis of the materials handling vehicle when moved from the first
angular orientation to the second angular orientation, and the second operator control
assembly may be rotated in an opposite direction about a second axis generally parallel
to the longitudinal axis of the materials handling vehicle when moved from the third
angular orientation to the fourth angular orientation.
[0011] The first support structure may comprise a first fixed housing portion and a first
movable housing portion, in which the first movable housing portion may be coupled
to and movable with the first operator control assembly and may be positioned to telescope
over the first fixed housing portion. The second support structure may comprise a
second fixed housing portion and a second movable housing portion, in which the second
movable housing portion may be coupled to and movable with the second operator control
assembly and may be positioned to telescope over the second fixed housing portion.
[0012] The first operator control assembly may be continuously movable in a vertical direction
between a first vertical position and a second vertical position, and the second operator
control assembly may be continuously movable in a vertical direction between a third
vertical position and a fourth vertical position.
[0013] At least one of the angular orientation or the vertical position of the first operator
control assembly may be adjustable independent of at least one of the angular orientation
or the vertical position of the second operator control assembly.
[0014] The first vertical adjustment assembly may comprise: a first mounting plate attached
to a support wall of the materials handling vehicle, a first rail member attached
to the first mounting plate, a first carriage assembly movably coupled to the first
rail member and coupled to the first fixture structure, and a first locking gas spring
coupled to the first fixture structure and the first mounting plate to control the
vertical position of the first operator control assembly. The second vertical adjustment
assembly may comprise: a second mounting plate attached to the support wall of the
materials handling vehicle, a second rail member attached to the second mounting plate,
a second carriage assembly movably coupled to the second rail member and coupled to
the second fixture structure, and a second locking gas spring coupled to the second
fixture structure and the second mounting plate to control the vertical position of
the second operator control assembly.
[0015] In accordance with a third aspect of the present disclosure, an operator control
system for a materials handling vehicle is provided, in which the materials handling
vehicle comprises an operator station having a generally horizontal floor surface
and a support structure and the operator control system comprises: an operator control
assembly and a vertical adjustment assembly coupled to the operator control assembly
to selectively support the operator control assembly at a plurality of vertical positions
relative to the generally horizontal floor surface. The operator control assembly
may comprise a housing mounted to the support structure, and a steering assembly for
steering the materials handling vehicle. The steering assembly may comprise a steering
control structure and a base structure from which the steering control structure extends,
in which the steering assembly may be movable with respect to the housing such that
the steering assembly can be positioned in at least one of first or second positions.
While in the first position, the steering control structure may extend from the base
structure generally in a first orientation, and while in the second position, the
steering control structure may extend from the base structure generally in a second
orientation different from the first orientation.
[0016] The base structure may comprise a base plate and a mount coupled to the base plate,
in which the mount may be pivotably mounted within a socket of the housing to enable
the steering assembly to be moved between the first and second positions.
[0017] When the steering assembly is positioned in the first position, the steering control
structure may be oriented at an acute angle relative to a vertical plane, in which
the vertical plane may be perpendicular to the generally horizontal floor surface
of the vehicle. When the steering assembly is positioned in the second position, the
steering control structure may be oriented at an acute angle relative to a horizontal
plane, in which the horizontal plane may be parallel to the generally horizontal floor
surface of the vehicle.
[0018] The operator control system may further comprise a lock assembly for locking the
steering assembly in the at least one of the first or second positions, in which the
lock assembly comprises a lock release structure for unlocking the lock assembly such
that the steering assembly can be moved between the at least one of the first or second
positions.
[0019] The steering assembly may move independently of the support structure and the housing,
such that the support structure and the housing remain in a same position when the
steering assembly is in the first position and the second position. The housing may
further comprise a control element area and the steering assembly may move independently
of the control element area.
[0020] The support structure may comprise a fixed housing portion and a movable housing
portion, in which the movable housing portion may be coupled to and movable with the
operator control assembly and may be positioned to telescope over the fixed housing
portion.
[0021] The operator control assembly may be continuously movable in a vertical direction
between a first vertical position and a second vertical position.
[0022] The vertical adjustment assembly may comprise: a mounting plate attached to a support
wall of the vehicle, a rail member attached to the mounting plate, a carriage assembly
movably coupled to the rail member and coupled to the fixture structure, and a locking
gas spring coupled to the fixture structure and the mounting plate to control the
vertical position of the operator control assembly.
[0023] In accordance with a fourth aspect of the present disclosure, an operator control
system for a materials handling vehicle is provided, in which the materials handling
vehicle comprises an operator station having a generally horizontal floor surface,
a first support structure, and a second support structure spaced apart from the first
support structure in a lateral direction, and the operator control system comprises:
a first operator control assembly and a second operator control assembly comprising
a second housing mounted to the second support structure. The first operator control
assembly may comprise a first housing mounted to the first support structure, and
a steering assembly for steering the materials handling vehicle. The steering assembly
may comprise a steering control structure and a base structure from which the steering
control structure extends, in which the steering assembly may be movable with respect
to the first housing such that the steering assembly can be positioned in at least
one of first or second positions. While in the first position, the steering control
structure may extend from the base structure generally in a first orientation, and
while in the second position, the steering control structure may extend from the base
structure generally in a second orientation different from the first orientation.
The operator control system may further comprise a first vertical adjustment assembly
coupled to the first operator control assembly to selectively support the first operator
control assembly at a plurality of vertical positions relative to the generally horizontal
floor surface, and a second vertical adjustment assembly coupled to the second operator
control assembly to selectively support the second operator control assembly at a
plurality of vertical positions relative to the generally horizontal floor surface.
[0024] The base structure may comprise a base plate and a mount coupled to the base plate,
in which the mount may be pivotably mounted within a socket of the housing to enable
the steering assembly to be moved between the first and second positions.
[0025] When the steering assembly is positioned in the first position, the steering control
structure may be oriented at an acute angle relative to a vertical plane, in which
the vertical plane may be perpendicular to the generally horizontal floor surface
of the vehicle. When the steering assembly is positioned in the second position, the
steering control structure may be oriented at an acute angle relative to a horizontal
plane, in which the horizontal plane may be parallel to the generally horizontal floor
surface of the vehicle.
[0026] The steering assembly may move independently of the first support structure and the
first housing, such that the first support structure and the first housing remain
in a same position when the steering assembly is in the first position and the second
position. The first housing further may comprise a control element area, and the steering
assembly may move independently of the control element area.
[0027] The first support structure may comprise a first fixed housing portion and a first
movable housing portion, in which the first movable housing portion may be coupled
to and movable with the first operator control assembly and may be positioned to telescope
over the first fixed housing portion. The second support structure may comprise a
second fixed housing portion and a second movable housing portion, in which the second
movable housing portion may be coupled to and movable with the second operator control
assembly and may be positioned to telescope over the second fixed housing portion.
[0028] The first operator control assembly may be continuously movable in a vertical direction
between a first vertical position and a second vertical position, and the second operator
control assembly may be continuously movable in a vertical direction between a third
vertical position and a fourth vertical position.
[0029] The vertical position of the first operator control assembly may be adjustable independent
of the vertical position of the second operator control assembly.
[0030] The vertical position of the second operator control assembly may be adjustable independent
of at least one of the vertical position of the first operator control assembly or
positioning of the steering assembly.
[0031] The first vertical adjustment assembly may comprise: a first mounting plate attached
to a support wall of the materials handling vehicle, a first rail member attached
to the first mounting plate, a first carriage assembly movably coupled to the first
rail member and coupled to the first fixture structure, and a first locking gas spring
coupled to the first fixture structure and the first mounting plate to control the
vertical position of the first operator control assembly. The second vertical adjustment
assembly may comprise: a second mounting plate attached to the support wall of the
materials handling vehicle, a second rail member attached to the second mounting plate,
a second carriage assembly movably coupled to the second rail member and coupled to
the second fixture structure, and a second locking gas spring coupled to the second
fixture structure and the second mounting plate to control the vertical position of
the second operator control assembly.
[0032] In accordance with a fifth aspect of the present disclosure, an operator control
system for a materials handling vehicle is provided, in which the materials handling
vehicle comprises an operator station having a support structure and the operator
control system comprises: an operator control assembly and a vertical adjustment assembly
coupled to the operator control assembly to selectively support the operator control
assembly at a plurality of vertical positions relative to the floorboard. The operator
control assembly may comprise a housing mounted to the support structure and including
a recess, a first elongate grip member mounted to the housing at at least one grip
mount location and extending over the recess, and a first control element mounted
to the housing within the recess, in which the first control element may be configured
to control a function of the materials handling vehicle. The first elongate grip member
may be replaceable with a second elongate grip member mounted to the housing at the
at least one grip mount location and extending over the recess and having at least
one of different dimensions or a different configuration than the first grip member.
[0033] The at least one grip mount location may comprise first and second grip mount locations,
in which the first grip mount location may be on a first side of the recess and the
second grip mount location may be on a second side of the recess opposite to the first
side of the recess.
[0034] The support structure may comprise a fixed housing portion and a movable housing
portion, in which the movable housing portion may be coupled to and movable with the
operator control assembly and may be positioned to telescope over the fixed housing
portion.
[0035] The operator control assembly may be continuously movable in a vertical direction
between a first vertical position and a second vertical position.
[0036] The vertical adjustment assembly may comprise: a mounting plate attached to a support
wall of the vehicle, a rail member attached to the mounting plate, a carriage assembly
movably coupled to the rail member and coupled to the fixture structure, and a locking
gas spring coupled to the fixture structure and the mounting plate to control the
vertical position of the operator control assembly.
[0037] In accordance with a sixth aspect of the present disclosure, an operator control
system for a materials handling vehicle is provided, in which the materials handling
vehicle comprises an operator station having a support structure and the operator
control system comprises: an operator control assembly and a vertical adjustment assembly
coupled to the operator control assembly to selectively support the operator control
assembly at a plurality of vertical positions relative to the floorboard. The operator
control assembly may comprise a housing mounted to the support structure and including
a recess, a first elongate grip member mounted to the housing and extending over the
recess, and a first control element mounted to the housing within the recess, in which
the first control element may be configured to control a function of the materials
handling vehicle and may be positionable in a plurality of positions including two
end positions. The first elongate grip member may be replaceable with a second elongate
grip member extending over the recess and having at least one of different dimensions
or a different configuration than the first grip member, and/or the first control
element may be replaceable with a second control element that may be positionable
in a plurality of positions including two end positions and having at least one of
different dimensions or a different configuration than the first control element.
A gap between adjacent portions of one of the first or the second control element
and one of the first or the second grip member may fall within a range of from a minimum
clearance distance to a maximum reach distance with the first or the second control
element positioned in any one of its plurality of positions.
[0038] The first elongate grip member may be secured to the housing at first and second
grip mount locations, in which the first grip mount location may be on a first side
of the recess and the second grip mount location may be on a second side of the recess
opposite to the first side of the recess.
[0039] In accordance with a seventh aspect of the present disclosure, an operator control
system for a materials handling vehicle is provided, in which the materials handling
vehicle comprises an operator station having a floorboard and a support structure
and the operator control system comprises an operator control assembly comprising:
a housing mounted to the support structure, a vertical adjustment assembly coupled
to the operator control assembly to selectively support the operator control assembly
at a plurality of vertical positions relative to the floorboard, and at least one
of: a steering assembly for steering the materials handling vehicle or a fixture structure
coupled to the support structure to selectively support the operator control assembly
in a plurality of angular orientations relative to the support structure. The steering
assembly may comprise a steering control structure and a base structure from which
the steering control structure extends, in which the steering assembly may be movable
with respect to the housing such that the steering assembly can be positioned in at
least one of first or second positions. The steering control structure may extend
from the base structure generally in a first orientation while in the first position
and generally in a second orientation while in the second position, in which the second
orientation may be different from the first orientation.
[0040] In accordance with an eighth aspect of the present disclosure, an operator control
system for a materials handling vehicle is provided, in which the materials handling
vehicle comprises an operator station having a floorboard and a support structure
and the operator control system comprises an operator control assembly comprising:
a housing mounted to the support structure and including a recess, a vertical adjustment
assembly coupled to the operator control assembly to selectively support the operator
control assembly at a plurality of vertical positions relative to the floorboard,
and at least one of: a first control element mounted to the housing within the recess
and a first elongate grip member mounted to the housing at at least one grip mount
location and extending over the recess or a fixture structure coupled to the support
structure to selectively support the operator control assembly in a plurality of angular
orientations relative to the support structure. The first elongate grip member may
be replaceable with a second elongate grip member having at least one of different
dimensions or a different configuration than the first grip member, and the first
control element may be replaceable with a second control element that is positionable
in a plurality of positions including two end positions and having at least one of
different dimensions or a different configuration than the first control element.
[0041] In accordance with a ninth aspect of the present disclosure, an operator control
system for a materials handling vehicle is provided, in which the materials handling
vehicle comprises an operator station having a floorboard, a first support structure,
and a second support structure spaced apart from the first support structure in a
lateral direction, and the operator control system comprises a first operator control
assembly and a second operator control assembly. The first operator control assembly
may comprise: a first housing mounted to the first support structure, a first vertical
adjustment assembly coupled to the first operator control assembly to selectively
support the first operator control assembly at a plurality of vertical positions relative
to the floorboard, and at least one of: a steering assembly for steering the materials
handling vehicle or a first fixture structure coupled to the first support structure
to selectively support the first operator control assembly in a plurality of angular
orientations relative to the first support structure. The steering assembly may comprise
a steering control structure and a base structure from which the steering control
structure extends, in which the steering assembly may be movable with respect to the
housing such that the steering assembly can be positioned in at least one of first
or second positions. The steering control structure may extend from the base structure
generally in a first orientation while in the first position and generally in a second
orientation while in the second position, in which the second orientation may be different
from the first orientation. The second operator control assembly may comprise: a second
housing mounted to the second support structure and including a recess, a second vertical
adjustment assembly coupled to the second operator control assembly to selectively
support the second operator control assembly at a plurality of vertical positions
relative to the floorboard, and at least one of: a first control element mounted to
the housing within the recess and a first elongate grip member mounted to the housing
at at least one grip mount location and extending over the recess or a second fixture
structure coupled to the second support structure to selectively support the second
operator control assembly in a plurality of angular orientations relative to the second
support structure. The first elongate grip member may be replaceable with a second
elongate grip member having at least one of different dimensions or a different configuration
than the first grip member, and the first control element may be replaceable with
a second control element that is positionable in a plurality of positions including
two end positions and having at least one of different dimensions or a different configuration
than the first control element.
[0042] In accordance with a tenth aspect of the present disclosure, an operator control
system is provided for a materials handling vehicle, the materials handling vehicle
including an operator station having a support structure. The operator control system
comprises an operator control assembly comprising: a housing mounted to or integral
with the support structure, the housing including a recess; a first elongate grip
member mounted to the housing and extending over the housing recess; and a first control
element mounted to the housing within the recess, the first control element configured
to control a function of the materials handling vehicle and positionable in a plurality
of positions including two end positions. At least one of: the first elongate grip
member is replaceable with a second elongate grip member extending over the housing
recess and having at least one of different dimensions or a different configuration
than the first grip member; or the first control element is replaceable with a second
control element, the second control element being positionable in a plurality of positions
including two end positions and having at least one of different dimensions or a different
configuration than the first control element. A gap between adjacent portions of one
of the first or the second control element and one of the first or the second grip
member falls within a range of from a minimum clearance distance to a maximum reach
distance with the first or the second control element positioned in any one of its
plurality of positions.
[0043] The housing recess may have a curvilinear shape.
[0044] The first control element may be a switch or lever.
[0045] The first elongate grip member may be secured to the housing at first and second
grip mount locations, with the first grip mount location being on a first side of
the housing recess and the second grip mount location being on a second side of the
housing recess opposite to the first side of the housing recess.
[0046] The first elongate grip member may include a third control element configured to
control a function of the materials handling vehicle.
[0047] In accordance with an eleventh aspect of the present disclosure, an operator control
system is provided for a materials handling vehicle, the materials handling vehicle
including an operator station having a support structure. The operator control system
comprises an operator control assembly comprising: a housing mounted to or integral
with the support structure, the housing including a recess; a first elongate grip
member mounted to the housing at at least one grip mount location and extending over
the housing recess; and a first control element mounted to the housing within the
recess, the first control element configured to control a function of the materials
handling vehicle. The first elongate grip member is replaceable with a second elongate
grip member mounted to the housing at the at least one grip mount location and extending
over the housing recess and having at least one of different dimensions or a different
configuration than the first grip member.
[0048] The housing recess may have a curvilinear shape.
[0049] In accordance with a twelfth aspect of the present disclosure, an operator control
system is provided for a materials handling vehicle, the materials handling vehicle
including an operator station having a first support structure. The operator control
system comprises a first operator control assembly comprising: a first housing mounted
to or integral with the first support structure, the first housing comprising a socket;
and a steering assembly for steering the materials handling vehicle. The steering
assembly comprises a steering control structure and a base structure from which the
steering control structure extends. The base structure comprises a base plate and
a mount coupled to the base plate, the mount being pivotably mounted within the socket
of the first housing such that the steering assembly is movable between at least a
first position and a second position. When in the first position, the steering control
structure extends from the base structure generally in a first orientation, and when
in the second position, the steering control structure extends from the base structure
generally in a second orientation different from the first orientation.
[0050] The first housing may further comprise a control element area, and the steering assembly
may move independently of the control element area. An orientation of the control
element area with respect to the first support structure may remain unchanged regardless
of whether the steering control assembly is in the first position or the second position.
[0051] The mount may have a semi-spherical shape and the socket may have a corresponding
semi-spherical shape.
[0052] The base plate may include a plurality of indentations around a periphery of the
base plate.
[0053] When the steering assembly is positioned in the first position, the steering control
structure may be oriented at an acute angle relative to a vertical plane, wherein
the vertical plane is perpendicular to a generally horizontal floor surface of the
vehicle. When the steering assembly is positioned in the second position, the steering
control structure may be oriented at an acute angle relative to a horizontal plane,
wherein the horizontal plane is parallel to the generally horizontal floor surface
of the vehicle.
[0054] The operator control system may further comprise a lock assembly for locking the
steering assembly in the at least one of the first or second positions. The lock assembly
may comprise a lock release structure for unlocking the lock assembly such that the
steering assembly can be moved between the at least one of the first or second positions.
[0055] In accordance with a thirteenth aspect of the present disclosure, an operator control
system is provided for a materials handling vehicle. The materials handling vehicle
includes an operator station having a first support structure and a second support
structure, wherein the first and second support structures are spaced apart from one
another in a lateral direction of the materials handling vehicle, the lateral direction
being perpendicular to a longitudinal axis of the materials handling vehicle. The
operator control system comprises: a first operator control assembly supported on
the first support structure via a first fixture structure that selectively supports
the first operator control assembly in one of at least first and second angular orientations
relative to the first support structure; and a second operator control assembly supported
on the second support structure via a second fixture structure that selectively supports
the second operator control assembly in one of at least first and second angular orientations
relative to the second support structure. Positioning of the first and second operator
control assemblies in the respective first or second angular orientation is dependent
upon a spacing of the first support structure relative to the second support structure
in the lateral direction.
[0056] The first and second fixture structures may each comprise a mounting plate coupled
to the respective first or second support structure and a plurality of fasteners that
extend through openings provided in the mounting plate. The fasteners may couple respective
first and second housings of the first and second operator control assemblies to the
corresponding support structures.
[0057] Each mounting plate may comprise one or more first openings and one more second openings.
The first operator control assembly may be positioned at the first angular orientation
relative to the first support structure when the fasteners are received in the one
or more first openings of the mounting plate of the first fixture structure. The first
operator control assembly may be rotated about a first axis generally parallel to
a longitudinal axis of the materials handling vehicle when moved from the first angular
orientation to the second angular orientation such that the first operator control
assembly is mounted in the second angular orientation when the fasteners are received
in the one or more second openings.
[0058] The second operator control assembly may be positioned at the first angular orientation
relative to the second support structure when the fasteners are received in the one
or more first openings of the mounting plate of the second fixture structure. The
second operator control assembly may be rotated about a second axis generally parallel
to a longitudinal axis of the materials handling vehicle when moved from the first
angular orientation to the second angular orientation such that the second operator
control assembly is mounted in the second angular orientation when the fasteners are
received in the one or more second openings.
[0059] The first housing may have a curved lower surface that is received by a curved upper
surface of the first support structure and the second housing may have a curved lower
surface that is received by a curved upper surface of the second support structure.
[0060] For a narrower width vehicle, the first and second operator control assemblies may
be positioned in the first angular orientation, and for a wider width vehicle, the
first and second operator control assemblies may be positioned in the second angular
orientation.
[0061] In accordance with a fourteenth aspect of the present disclosure, an operator control
system is provided for a materials handling vehicle, the materials handling vehicle
comprising an operator station having a generally horizontal floor surface and a support
structure. The operator control system comprises an operator control assembly supported
by the support structure, and a vertical adjustment assembly coupled to the operator
control assembly to selectively support the operator control assembly at a plurality
of vertical positions on the support structure relative to the generally horizontal
floor surface. The operator control system further comprises at least one of:
a housing mounted to the support structure; and a steering assembly for steering the
materials handling vehicle, the steering assembly comprising a steering control structure
and a base structure from which the steering control structure extends, wherein the
steering assembly is movable with respect to the housing such that the steering assembly
can be positioned in at least one of first or second positions. While in the first
position, the steering control structure extends from the base structure generally
in a first orientation. While in the second position, the steering control structure
extends from the base structure generally in a second orientation different from the
first orientation;
a fixture structure coupled to the support structure to selectively support the operator
control assembly in a plurality of angular orientations relative to the support structure;
or
a housing mounted to the support structure, the housing comprising a recess; a first
elongate grip member mounted to the housing at at least one grip mount location and
extending over the recess; and a first control element mounted to the housing within
the recess, the first control element configured to control a function of the materials
handling vehicle. The first elongate grip member is replaceable with a second elongate
grip member mounted to the housing at the at least one grip mount location and extending
over the recess and having at least one of different dimensions or a different configuration
than the first grip member.
[0062] Various aspects and embodiments of the present disclosure address various technical
problems associated with a need for adjustable operator controls to provide ergonomic
positioning for operators of varying height and to accommodate operator preference.
The present disclosure provides a first technical solution which involves a steering
assembly that is movable between at least two positions and is lockable in each position.
The movable steering assembly rotates between positions to allow for quick and easy
adjustment to accommodate varying operator heights and provide flexibility of use,
e.g., adjustment based on operator preference, driving conditions, and/or a task to
be performed. The steering assembly also moves independently of other control structures
in the materials handling vehicle to avoid obstruction of the operator compartment
and to prevent inadvertent contact between the steering assembly and the operator
or other objects. Another technical solution involves an operator control assembly
with one or more interchangeable components that may be replaced with a corresponding
component having a different dimension and/or configuration to ensure ergonomic positioning
and better accessibility to control elements. These components may be common across
multiple different types or models of materials handing vehicles. The operator control
assembly also includes an elongate grip member that provides a stable grip for the
operator during operation of the materials handling vehicle. A further technical solution
involves positioning of an operator control assembly at two or more angular orientations
with respect to a support structure in order to provide ergonomic hand positioning
based on, for example, a width of the materials handling vehicle. Yet another technical
solution involves adjusting a vertical position of an operator control assembly to
provide ergonomic positioning of the operator control assembly for different operators
and to accommodate operator preference. Each of these adjustment features may be used
alone or in combination with one or more other adjustment features. Further technical
problems and corresponding solutions are set out herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0063]
Fig. 1 is a perspective view of a materials handling vehicle including an operator
control system according to embodiments;
Fig. 2 is a front elevation view of the operator control system shown in Fig. 1;
Fig. 2A is a back elevation view of an operator control system according to embodiments;
Fig. 3 is a perspective view of an operator control assembly of the operator control
system shown in Fig. 2;
Fig. 3A is a perspective view of an operator control assembly according to embodiments;
Figs. 4 and 5 are perspective views of an operator control assembly of the operator
control system shown in Fig. 2;
Figs. 6-8 are cross sectional views of the operator control assembly shown in Figs.
3-6;
Fig. 9 is a perspective view of another operator control assembly of the operator
control system shown in Fig. 2;
Figs. 10A and 10B are perspective views of operator control assemblies according to
embodiments;
Figs. 11A-11F are cross sectional views of operator control assemblies according to
embodiments;
Figs. 12A and 12B are back elevation views of the operator control system shown in
Fig. 2;
Figs. 13A-13D are enlarged views illustrating operator control assemblies of the operator
control system of Figs. 12A and 12B;
Fig. 14 is a perspective view of an operator control assembly according to embodiments;
Fig. 15 is a perspective view of a materials handling vehicle including a platform
assembly, operator control assembly, and non-horizontal viewing window according to
embodiments;
Fig. 16 is a back elevation view of a platform assembly with the non-horizonal viewing
window shown in Fig. 15;
Fig. 17 is a back perspective view of a platform assembly with the non-horizontal
viewing window shown in Fig. 15;
Figs. 17A-17C are perspective views showing overhead guard extensions according to
embodiments;
Fig. 18 is a back elevation view of the materials handling vehicle of Fig. 15 with
the operator compartment and non-horizontal viewing window, shown in an elevated position;
Fig. 19A is a partial cross-sectional view of the materials handling vehicle of Fig.
15, showing the mast assembly, non-horizontal viewing window, and the space between;
Fig. 19B is a cross-sectional view of Fig. 19A at line 19B-19B showing the mast assembly,
non-horizontal viewing window, and the space between;
Fig. 20 is a partial front elevation view of the platform assembly shown in Fig. 15
with the non-horizontal viewing window according to embodiments;
Fig. 21 is a cross-sectional view of the platform assembly of Fig. 20 at line 21-21
according to embodiments;
Fig. 21A is an enlarged view taken from Fig. 21;
Fig. 22 is a partial front elevation view of the platform assembly with the non-horizontal
viewing window according to embodiments;
Fig. 23 is a cross-sectional view of the platform assembly of Fig. 22 at line 23-23
according to embodiments;
Fig. 23A is an enlarged view taken from Fig. 23;
Fig. 24 is a partial top view from the operator's point of view with the platform
assembly in the elevated position of Fig. 25 and including an enlarged view of what
the operator sees through a portion of the viewing window;
Fig. 25 is a side elevation view of the materials handling vehicle of Fig. 15 with
the mast assembly in a retracted position and the operator compartment in an elevated
position according to embodiments, showing view lines through the non-horizontal viewing
window;
Fig. 26 is a side elevation view of the materials handling vehicle of Fig. 15 in a
fully elevated position according to embodiments, showing view lines through the non-horizontal
viewing window;
Fig. 27 is a perspective view of a materials handling vehicle where the platform assembly
further includes an outer support wall, outer viewing windows, and fork carriage assembly
movable relative to the outer support wall, according to embodiments;
Fig. 28 is a partial elevation view of the platform assembly shown in Fig. 27 including
the outer support wall, outer viewing windows, and operator control assemblies, viewed
from the operator compartment according to embodiments;
Fig. 28A is a cross-sectional view of Fig. 28 at line 28A-28A showing the movable
fork carriage assembly;
Fig. 28B is a cross-sectional view of Fig. 28 at line 28B-28B showing the movable
fork carriage assembly in an elevated, upper position;
Fig. 29 is a partial bottom perspective view of the platform assembly of Fig. 27 with
the fork carriage assembly in a lowered position and the outer support wall separated
from the floorboard;
Fig. 30 is a partial front elevation view of the platform assembly including the outer
support wall, outer viewing window, and operator control assembly, viewed from the
operator compartment according to embodiments;
Fig. 31 is a side elevation view of the materials handling vehicle of Fig. 27 shown
in both a partially elevated position and a fully elevated position according to embodiments,
illustrating view lines through the non-horizontal viewing window in the outer support
wall;
Fig. 32 is a detailed top, perspective view of the materials handling vehicle of Fig.
27 comprising an inner operator control system and an outer operator control system;
Fig. 33 is a front elevation view of the inner operator control system shown in Fig.
32;
Figs. 34 and 35 are back elevation views of the operator control system shown in Fig.
33;
Fig. 36 is a front elevation view of one of the operator control assemblies shown
in Fig. 33 in which a portion of a housing is removed;
Fig. 37 is a perspective view of a vertical adjustment assembly for adjusting a vertical
position of the operator control assembly of Fig. 36; and
Fig. 38 is an exploded view of the vertical adjustment assembly shown in Fig. 37.
BEST MODE FOR CARRYING OUT THE INVENTION
[0064] The following text sets forth a broad description of numerous different embodiments
of the present disclosure. The description is to be construed as exemplary only and
does not describe every possible embodiment since describing every possible embodiment
would be impractical, if not impossible, and it will be understood that any feature,
characteristic, component, composition, ingredient, product, step or methodology described
herein can be deleted, combined with or substituted for, in whole or part, any other
feature, characteristic, component, composition, ingredient, product, step or methodology
described herein. It should be understood that multiple combinations of the embodiments
described and shown are contemplated and that a particular focus on one embodiment
does not preclude its inclusion in a combination of other described embodiments. Numerous
alternative embodiments could also be implemented, using either current technology
or technology developed after the filing date of this patent, which would still fall
within the scope of the claims. All publications and patents cited herein are incorporated
herein by reference.
[0065] Referring now to the drawings, Fig. 1 illustrates a materials handling vehicle 10
constructed in accordance with embodiments. In the illustrated embodiment, the vehicle
10 comprises a stockpicker, but could be another type of materials handing vehicle.
The vehicle 10 includes a power unit 12, a platform assembly 14 including an operator
compartment 16, and a load handling assembly 18. The power unit 12 includes a power
source, such as a battery unit 20. The vehicle 10 includes a plurality of wheels 22
on which the vehicle 10 travels (one or more additional wheels are located underneath
the power unit 12 but are not shown in Fig. 1). The load handling assembly 18 comprises
a mast assembly 30 coupled to the power unit 12 on which the platform assembly 14
moves vertically, and further comprises fork structure 32 comprising a pair of forks
32A, 32B. The mast assembly 30 comprises one or more mast sections. Mast sections
may also be referred to herein as weldments. The exemplary mast assembly 30 illustrated
in Fig. 1 is a three-stage mast assembly, in which a carriage to which the platform
assembly 14 is attached, is raised via a primary ram/cylinder assembly coupled to
the third mast section until it contacts the top of a third stage mast section, wherein
hydraulic pressure in secondary ram/cylinder assemblies of the mast assembly 30 causes
a second stage mast section and the third stage mast section to begin to raise. The
first stage mast section is fixed to the power unit 12 and to a pair of outriggers
34 holding the wheels 22. As the second stage mast section is raised, the third stage
mast section raises twice the distance.
[0066] The operator compartment 16 includes a floor surface 40 upon which an operator stands
while operating the vehicle 10 from an operator station 42 located in the operator
compartment 16. An operator presence sensor 44 in the form of a pressure switch that
senses an operator's foot is provided in the floor surface 40. According to embodiments,
one or more functions of the vehicle, such as traveling movement, raising/lowering
the load handling assembly 18, etc. may be disabled unless the operator presence sensor
indicates the presence of the operator in the operator compartment 16. First and second
side restraints 46, 48 are provided at opposed left and right sides LS, RS of the
operator compartment 16, the left and right sides LS, RS being spaced apart from one
another in a lateral direction L
D that is perpendicular to a longitudinal axis L
A of the vehicle 10.
[0067] The operator station 42 may include one or more bins 50 in which the operator can
store items. The bins 50 may be positioned anywhere in the operator station 42 and
may be movable as desired. The operator station 42 further comprises a first support
structure 52 and a second support structure 54 spaced apart from each other in the
lateral direction L
D, see Figs. 1 and 2. The first and second support structures 52, 54 are separated
by a recessed portion 56 of the vehicle 10 that defines an open area extending downward
from upper surfaces 52A, 54A of the first and second support structures 52, 54 toward
the floor surface 40. In the illustrated embodiment, the open area extends to just
above one of the bins 50.
[0068] An operator control system 60 is provided in the operator station 42. The operator
uses the operator control system 60 to drive the vehicle 10 and to control one or
more other vehicle functions as will be described in greater detail herein. With reference
to Fig. 2, the operator control system 60 comprises a first operator control assembly
62 associated with the first support structure 52 and a second operator control assembly
64 associated with the second support structure 54. In the illustrated embodiment,
the first operator control assembly 62 is provided to control steering of the vehicle
10 and optionally to control additional vehicle functions, and the second operator
control assembly 64 is provided to control load handling assembly lift and lower functions
and optionally other vehicle functions, as will be described in greater detail herein.
[0069] With reference to Figs. 2-5, the first operator control assembly 62 comprises a first
housing 66 separate from the first support structure 52 but mounted to the first support
structure 52 via fasteners, adhesive, etc., although the first housing 66 could be
integral with the first support structure 52 as shown in the alternate embodiment
illustrated in Fig. 2A. One or more control elements 68, such as buttons, switches,
levers, etc., may be provided on a control element area 70 of the first housing 66
for generating control signals to a vehicle electronic processor or controller to
control respective functions of the vehicle 10, including, for example, accessories
such as lights, fans, etc., function overrides, function confirmations, etc., i.e.,
the vehicle processor or controller may control functions of the vehicle 10 based
on the control signals from the control elements 68. The control element area 70 may
be generally planar as shown in Figs. 2-5 or non-planar, and may include any number
of control elements or no control elements.
[0070] The first housing 66 also includes a socket 72 or cavity that extends downwardly
from the control element area 70 in a direction toward the floor surface 40 of the
operator compartment 16 and inwardly into the first housing 66. The socket 72 may
have a semi-spherical shape.
[0071] The first operator control assembly 62 further comprises a steering assembly 80 for
steering the vehicle 10. The steering assembly 80 comprises a base structure 82 and
a steering control structure 84 that extends outwardly from the base structure 82.
The base structure 82 comprises a base plate 86 and a mount 88 coupled to the base
plate 86, wherein the steering control structure 84 extends outwardly from the base
plate 86. The base plate 86 may have a generally circular shape and is rotatably coupled
to the mount 88 such that the base plate 86 can rotate relative to the mount 88. Turning
of the vehicle 10 is accomplished by the operator using the steering control structure
84 to rotate the base plate 86 relative to the mount 88, i.e., the vehicle processor
or controller may control a steer motor of the vehicle 10 based on control signals
from the steering assembly 80 to set the turning angle of the vehicle 10. The base
plate 86 may optionally include a plurality of indentations 90 around a periphery
thereof. The operator may engage one or more of the indentations 90 with one or more
fingers to rotate the base plate 86 relative to the mount 88 to turn the vehicle 10.
[0072] The steering control structure 84 may comprise a knob as shown in Figs. 1-6 (Fig.
3A illustrates the steering control structure 84 in the form of a smaller knob in
accordance with an embodiment), although the steering control structure 84 may have
any suitable shape and configuration. In the illustrated exemplary embodiment, the
steering control structure 84 includes a plurality of gripping elements 92 coupled
to an outer surface of a main body 84A of the knob. The gripping elements 92 may be
adhesively secured to the outer surface of the main body 84A of the knob or mounted
within corresponding recesses within the main body 84A of the knob. The gripping elements
92 may be formed from a polymeric material different from that of the main body 84A,
such as a thermoplastic elastomer (TPE), which enhances gripping between the operator
and the knob during operation to steer the vehicle 10 using the steering assembly
80. The steering control structure 84 may be rotatably mounted to the base plate 86
such that the steering control structure 84 can rotate relative to the base plate
86. According to this aspect, the operator does not need to let go of the steering
control structure 84 while turning the vehicle 10 using the steering control structure
84, since the steering control structure 84 rotates relative to the base plate 86
and the base plate 86 rotates relative to the mount 88.
[0073] As seen most clearly in Figs. 3-6, the mount 88 is received in the socket 72 of the
first housing 66 and may have a semi-spherical shape corresponding to the semi-spherical
shape of the socket 72. The mount 88 may be secured to the first housing 66 via a
pair of laterally spaced apart pivot supports or pins 100A, 100B, see Fig. 6. The
pivot supports 100A, 100B permit the steering assembly 80 to pivotably rotate relative
to the first housing 66, such that the steering assembly 80 is movable with respect
to the first housing 66 and can be positioned in a plurality of different positions.
According to one exemplary embodiment, the steering assembly 80 is movable between
first and second positions, and can be locked in these two positions via a lock assembly
104, which will be described below.
[0074] While in the first position, shown in Figs. 2, 3, and 5-7, the steering control structure
84 extends from the base structure 82 generally in a first orientation. In the first
orientation, the steering control structure 84 is oriented at a first angle α relative
to a first vertical plane V
P, see Fig. 7, wherein the first angle α may be an acute angle. With reference to Fig.
1, the vertical plane V
P is perpendicular to the floor surface of the vehicle 10, which lies on a generally
horizontal plane H
P. While in the second position, shown in Figs. 4 and 8, the steering control structure
84 extends from the base structure 82 generally in a second orientation. In the second
orientation, the steering control structure 84 is oriented at a second angle β relative
to the generally horizontal plane H
P, see Fig. 8, wherein the second angle β may be an acute angle. According to one non-limiting
exemplary working embodiment, the first angle α may be about 0 degrees to about 40
degrees (this example angle range includes zero (0) degrees), and the second angle
β may be about -10 degrees to about 30 degrees (this example angle range includes
zero (0) degrees as shown in Fig. 8, where the second angle β is parallel to the generally
horizontal plane H
P). According to another non-limiting exemplary working embodiment, the first angle
α may be about 10 degrees to about 30 degrees, and the second angle β may be about
-5 degrees to about 15 degrees (this example angle range includes zero (0) degrees
as shown in Fig. 8, where the second angle β is parallel to the generally horizontal
plane H
P). In the first position, the steering control structure 84 and the base plate 86
rotate relative to the mount 88 in a plane that is closer to the generally horizontal
plane H
P than to the vertical plane V
P, and in the second position, the steering control structure 84 and the base plate
86 rotate relative to the mount 88 in a plane that is closer to the vertical plane
V
P than to the generally horizontal plane H
P.
[0075] With reference to Figs. 6-8, the lock assembly 104 comprises a lock release structure
110 having an actuating portion 112 that is actuated by an operator to unlock the
lock assembly 104 such that the steering assembly 80 can be moved between its plurality
of positions. In the illustrated embodiment, when the operator presses the actuating
portion 112, a locking protuberance 114 of the lock release structure 110 is withdrawn
from a respective locking slot 116A or 116B formed in the mount 88 into a released
position, wherein each locking slot 116A, 116B corresponds to a corresponding position
of the steering assembly 80. In the illustrated embodiment having the first and second
steering assembly positions discussed above, the mount 88 includes two locking slots
116A and 116B, one locking slot 116A corresponding to the first position of the steering
assembly 80 and the other locking slot 116B corresponding to the second position of
the steering assembly 80. If more steering assembly positions are desired, the mount
88 can include additional locking slots to lock the steering assembly 80 into the
different positions. When the locking protuberance 114 is withdrawn from a locking
slot 116A or 116B, i.e., when the lock assembly 104 is moved into the released position,
pivoting movement of the steering assembly 80 relative to the mount 88 is permitted,
and when the locking protuberance 114 is inserted into a locking slot 116A or 116B,
i.e., when the lock assembly 104 is in a locked position, pivoting movement of the
steering assembly 80 relative to the mount 88 is prevented. Fig. 7 depicts the lock
assembly 104 in a locked position with the steering assembly 80 in the first position,
and Fig. 8 depicts the lock assembly 104 in a locked position with the steering assembly
80 in the second position.
[0076] The lock assembly 104 may further comprise a spring 118 that biases the lock release
structure 110 toward the locked position, such that the locking protuberance 114 is
inserted into a locking slot 116A or 116B if the locking protuberance 114 is properly
aligned with a locking slot 116A or 116B.
[0077] The lock assembly 104 may additionally comprise a sensor 120, such as a snap action
microswitch sensor, for sensing if the steering assembly 80 is in one of the first
or second locked positions or is in the released position. The sensor 120 may function,
for example, by sensing whether the lock assembly 104 is in the released position
or the locked position, or by sensing a surface on the lock release structure 110.
For example, when the locking protuberance 114 of the lock release structure 110 has
been moved out of one of the locking slots 116A and 116B, such that the locking protuberance
114 may be in engagement with an outer surface 88A of the mount 88, the sensor 120
will sense the lock release structure 110 in its released position and provide a corresponding
signal to the vehicle electronic processor or controller. One or more functions of
the vehicle 10, such as travelling movement, raising/lowering the load handling assembly
18, etc., may be disabled by the vehicle processor or controller if the sensor 120
detects that the steering assembly 80 is not locked in one of the first or second
positions.
[0078] The steering assembly 80 may move independently of the first support structure 52
and the first housing 66, which helps to keep the operator compartment 16 free of
obstruction and to prevent inadvertent contact between the operator control assembly
62 and the operator or other object(s), particularly when the steering assembly 80
is in the second position. For example, when the steering assembly 80 pivots about
the pivot supports 100A, 100B from the first position (shown in Figs. 3 and 5-7) to
the second position (shown in Figs. 3A, 4, and 8), it can be seen that only the steering
assembly 80 moves. The first support structure 52 and the first housing 66 remain
in a same position when the steering assembly 80 is in the first position, as compared
to when the steering assembly 80 is in the second position, such that these structures
do not protrude into the operator compartment 16. Additionally, because the steering
assembly 80 moves independently of the control element area 70 of the first housing
66, an orientation of the control element area 70 with respect to the first support
structure 52 is the same when the steering assembly 80 is in the first position, as
compared to when the steering assembly 80 is in the second position, such that the
control element area 70 may be easier for the operator to utilize while operating
the vehicle 10.
[0079] Turning now to Fig. 9, the second operator control assembly 64 comprises a second
housing 130 separate from the second support structure 54 but mounted to the second
support structure 54 (see Fig. 2) via fasteners, adhesive, etc., although the second
housing 130 could be integral with the second support structure 54, as shown in the
alternate embodiment illustrated in Fig. 2A. One or more control elements 132, such
as buttons, switches, levers, etc., may be provided on a control element area 134
of the second housing 130 for generating control signals to the vehicle processor
or controller to control respective functions of the vehicle 10, such as, for example,
a horn, an emergency stop, a control for an interactive display, etc., i.e., the vehicle
processor or controller may control functions of the vehicle 10 based on the control
signals from the control elements 132. The control element area 134 may include any
number of control elements or no control elements.
[0080] The second operator control assembly 64 further comprises a housing recess 140 that
extends downwardly from the control element area 134 in a direction toward the floor
surface 40 of the operator compartment 16. The housing recess 140 may have a curvilinear
shape.
[0081] A control element 142 of the second operator control assembly 64 is mounted to the
second housing 130 and extends outwardly from the housing recess 140. In the illustrated
embodiment, the control element 142 comprises a base portion 144 and switch or lever
146 extending from the base portion 144. The control element 142 generates corresponding
control signals to the vehicle processor or controller to control lift and lower functions
of the load handling assembly 18, although the control element 142 could be used for
other functions as desired. The control element 142 is positionable in a plurality
of positions including two end positions, wherein a first one of the two end positions
comprises a position in which the control element 142 is pushed forward until it reaches
a first stop limit, and a second one of the two end positions comprises a position
in which the control element 142 is pulled backward until it reaches a second stop
limit. The control element 142 may also be positionable in other positions between
the two end positions, including in default position, wherein the control element
142 may be located in a default position when not being pushed or pulled toward one
of the two end positions.
[0082] The second operator control assembly 64 further comprises an elongate grip member
150 mounted to the second housing 130 and extending over the housing recess 140. The
grip member 150 is mounted to the second housing 130 at least one grip mount location
proximate to the housing recess 140. In the illustrated embodiment, the grip member
150 is fixedly mounted to the second housing 130 at first and second grip mount locations
152A, 152B located on opposed lateral sides of the housing recess 140. The grip member
150 may be grasped by the operator's hand while the operator is driving the vehicle
10 and/or when the operator is operating the control element 142.
[0083] As shown in Fig. 9, a gap G is defined between a surface of the control element 142
located closest to the grip member 150 and a surface of the grip member 150 located
closest to the control element 142. The gap G is at all times preferably within a
range of from a minimum clearance distance to a maximum reach distance. That is, the
gap G is preferably always within this range whether the control element 142 is positioned
in the first end position, the second end position, the default position, or any position
between these defined positions. The range is selected such that the operator's finger
will not be pinched between the control element 142 and the grip member 150 while
the control element 142 is in any position, i.e., the gap G is greater than or equal
to the minimum clearance distance, but also such that the control element 142 in any
position is within reach of the operator's finger while grasping the grip member 150,
i.e., the gap G is less than or equal to the maximum reach distance. According to
one non-limiting exemplary working embodiment, the minimum clearance distance may
be about 15 mm, and the maximum reach distance may be about 50 mm, and according to
another non-limiting exemplary working embodiment, the minimum clearance distance
may be about 30 mm, and the maximum reach distance may be about 40 mm, although these
values may be different than the exemplary values provided, such as, for example,
when the vehicle 10 is intended for use by operators wearing thick gloves, in which
case these values may be larger than the exemplary values provided.
[0084] According to one embodiment, one or both of the first (or original) control element
142 and/or the grip member 150 can be removed and replaced with a second (or replacement)
control element and/or grip member while the gap G is maintained within the range
between the minimum clearance distance and the maximum reach distance regardless of
whether the original or replacement components are in place. The replacement control
element and/or replacement grip member may have different dimensions and/or different
configurations than the original (replaced) control element 142 and/or grip member
150. Figs. 10A to 11F illustrate this aspect.
[0085] In a first embodiment of Figs. 10A and 11A-11C, the second operator control assembly
64 includes an original control element 142 and an original grip member 150, also
referred to herein as a first control element 142 and a first grip member 150. Fig.
11A shows the first control element 142 in the first end position, Fig. 11B shows
the first control element 142 in the second end position, and Fig. 11C shows the first
control element 142 in the default position. While the first control element 142 is
in the first end position shown in Fig. 11A, the gap G is a first distance that is
greater than the minimum clearance distance (depicted in Fig. 11A as MCD). While the
first control element 142 is in the second end position shown in Fig. 11B, the gap
G is a second distance less than the maximum reach distance (depicted in Fig. 11B
as MRD). While the first control element 142 is in the default position shown in Fig.
11C, the gap G is a third distance intermediate the first and second distances.
[0086] In a second embodiment of Figs. 10B and 11D-11F, the second operator control assembly
64 includes a replacement control element 142' and a replacement grip member 150',
also referred to herein as a second control element 142' and a second grip member
150'. Each of the second control element 142' and the second grip member 150' have
at least one of different dimensions and/or different configurations than the first
control element 142 and the first grip member 150. Fig. 11D shows the second control
element 142' in the first end position, Fig. 11E shows the second control element
142' in the second end position, and Fig. 11F shows the second control element 142'
in the default position. While the second control element 142' is in the first end
position shown in Fig. 11D, the gap G is a first distance that is greater than the
minimum clearance distance (depicted in Fig. 11D as MCD'). While the second control
element 142' is in the second end position shown in Fig. 11E, the gap G is a second
distance less than the maximum reach distance (depicted in Fig. 11E as MRD'). While
the second control element 142' is in the default position shown in Fig. 11F, the
gap G is a third distance intermediate the first and second distances.
[0087] One of the first control element 142 or the first grip member 150 may also be used
with one of the second control element 142' or the second grip member 150', wherein
the two installed components are always spaced from one another such that the gap
G is greater than or equal to the minimum clearance distance and less than or equal
to the maximum reach distance. Additional replacement control elements and/or grip
members (not specifically shown) having at least one of different dimensions and/or
configurations than the first and second control elements 142, 142' and grip members
150, 150' may also be installed, wherein the two installed components are always spaced
from one another such that the gap G is greater than or equal to the minimum clearance
distance and less than or equal to the maximum reach distance. The curvilinear shape
of the housing recess 140 takes part in allowing different control elements to be
used while maintaining the gap G within the aforementioned range, since the curvilinear
shape at least in part sets the angle of the installed control element relative to
the grip member. That is, positioning the control element in different locations along
the curved surface of the curvilinear shape of the housing recess 140 and/or using
control element base portions having different dimensions and/or configurations will
modify the angle of the control element relative to the grip member.
[0088] The grip member 150 (and/or a replacement grip member) may include an additional
control element 160 as shown in Figs. 2, 9, 10A, and 10B. The additional control element
160 may generate control signals to the vehicle processor or controller to control
a vehicle function such as, for example, the traveling direction of the vehicle 10,
i.e., the vehicle processor or controller may control a traction motor of the vehicle
10 based on the control signals from the control element 160 to set the traveling
direction of the vehicle 10.
[0089] Turning now to Figs. 12A and 12B, the operator control system 60 may optionally include
first and second fixture structures 180, 182 to selectively allow one or both of the
first and/or second operator control assemblies 62, 64 to be positioned in multiple
respective positions. The first and second fixture structures 180, 182 may be coupled
to or integral with the respective first and second support structures 52, 54.
[0090] The first fixture structure 180 comprises a mounting plate 184 coupled to or integral
with the first support structure 52. The mounting plate 184 may be an elongate plate
extending in the vertical direction from the first support structure 52 to the first
housing 66 of the first operator control assembly 62. With reference to Figs. 13A
and 13B, the first fixture structure 180 further comprises a plurality of fasteners
186, such as bolts, that selectively extend through first openings 188A or second
openings 188B provided in the mounting plate 184 and into corresponding openings 190
formed in the backside of the first housing 66 to couple the first housing 66 to the
first support structure 52. The first fixture structure 180 can support the first
operator control assembly 62 in a first orientation relative to the first support
structure 52 shown in Figs. 12B and 13B by inserting the fasteners 186 through the
first openings 188A in the mounting plate 184 and into the openings 190 in the first
housing 66, or the first fixture structure 180 can support the first operator control
assembly 62 in a second orientation relative to the first support structure 52, the
second orientation different than the first orientation, as shown in Figs. 12A and
13A by inserting the fasteners 186 through the second openings 188B in the mounting
plate 184 and into the openings 190 in the first housing 66. While in the first orientation,
the first operator control assembly 62 is positioned at a first angular orientation
relative to the first support structure 52, and while in the second orientation, the
first operator control assembly 62 is positioned at a second angular orientation relative
to the first support structure 52 different than the first angular orientation. When
moved from the first angular orientation to the second angular orientation, the first
operator control assembly 62 is rotated about a first axis A
1 (see Fig. 7, noting that the first axis A
1 extends into the page in the views illustrated in Figs. 12A-13B) that is generally
parallel to the longitudinal axis L
A of the vehicle 10. According to one non-limiting exemplary working embodiment, the
first operator control assembly 62 may move through an angle of about -10 degrees
to about 10 degrees relative to the vertical direction when moving from the first
angular orientation to the second angular orientation, and according to another non-limiting
exemplary working embodiment, the first operator control assembly 62 may move through
an angle of about -5 degrees to about 5 degrees relative to the vertical direction
when moving from the first angular orientation to the second angular orientation.
[0091] As shown in Fig. 2, the upper surface 52A of the first support structure 52 according
to this embodiment may be a curved upper surface 52A, which corresponds to a curved
lower surface 66A of the first housing 66. The corresponding curved surfaces 52A,
66A allow the first operator control assembly 62 to be moved between the first and
second orientations while maintaining a close fit between the first support structure
52 and the first housing 66.
[0092] Referring back to Figs. 12A and 12B, the second fixture structure 182 comprises a
mounting plate 204 coupled to or integral with the second support structure 54. The
mounting plate 204 may be an elongate plate extending in the vertical direction from
the second support structure 54 to the second housing 130 of the second operator control
assembly 64. With reference to Figs. 13C and 13D, the second fixture structure 182
further comprises a plurality of fasteners 206, such as bolts, that selectively extend
through first openings 208A or second openings 208B provided in the mounting plate
204 and into corresponding openings 210 formed in the backside of the second housing
130 to couple the second housing 130 to the second support structure 54. The second
fixture structure 182 can support the second operator control assembly 64 in a first
orientation relative to the second support structure 54 shown in Figs. 12B and 13D
by inserting the fasteners 206 through the first openings 208A in the mounting plate
204 and into the openings 210 in the second housing 130, or the second fixture structure
182 can support the second operator control assembly 64 in a second orientation relative
to the second support structure 54, the second orientation different than the first
orientation, as shown in Fig. 12A and 13C by inserting the fasteners 206 through the
second openings 208B in the mounting plate 204 and into the openings 210 in the second
housing 130. While in the first orientation, the second operator control assembly
64 is positioned at a first angular orientation relative to the second support structure
54, and while in the second orientation, the second operator control assembly 64 is
positioned at a second angular orientation relative to the second support structure
54 different than the first angular orientation. When moved from the first angular
orientation to the second angular orientation, the second operator control assembly
64 is rotated about a second axis A
2 (see Fig. 9, noting that the second axis A
2 extends into the page in the views illustrated in Figs. 12A, 12B, 13C, and 13D) that
is generally parallel to the longitudinal axis L
A of the vehicle 10. According to one non-limiting exemplary working embodiment, the
second operator control assembly 64 may move through an angle of about -10 degrees
to about 10 degrees relative to the vertical direction when moving from the first
angular orientation to the second angular orientation, and according to another non-limiting
exemplary working embodiment, the first operator control assembly 62 may move through
an angle of about -5 degrees to about 5 degrees relative to the vertical direction
when moving from the first angular orientation to the second angular orientation.
[0093] The first and second support structures 52 and 54 may be positioned closer to one
another in a narrow width vehicle, e.g., vehicles having a width equal to or less
than 40 inches, and further away from one another in a wide width vehicle, e.g., vehicles
having a width equal to or greater than 42 inches. To provide preferred ergonomic
hand positioning for a narrower width vehicle, the first operator control assembly
62 may be positioned in the first angular orientation (shown in Fig. 12B), and to
provide preferred ergonomic hand positioning for a wider width vehicle, the first
operator control assembly 62 may be positioned in the second angular orientation (shown
in Fig. 12A).
[0094] As shown in Fig. 2, the upper surface 54A of the second support structure 54 according
to this embodiment may be a curved upper surface 54A, which corresponds to a curved
lower surface 130A of the second housing 130. The corresponding curved surfaces 54A,
130A allow the second operator control assembly 64 to be moved between the first and
second orientations while maintaining a close fit between the second support structure
54 and the second housing 130.
[0095] Fig. 14 illustrates a second operator control assembly 64 according to additional
embodiments. The second operator control assembly 64 according to Fig. 14 comprises
a second housing 130 and one or more control elements 132, such as buttons, switches,
levers, etc., provided on a control element area 134 of the second housing 130 for
generating control signals to the vehicle processor or controller to control respective
functions of the vehicle 10, such as, for example, an emergency stop, a control for
an interactive display, etc. i.e., the vehicle processor or controller may control
functions of the vehicle based on the control signals from the control elements 132.
The control element area 134 may include any number of control elements or no control
elements.
[0096] The operator control assembly 64 further comprises a housing recess 140 that extends
downwardly from the control element area 134 in a direction toward the floor surface
40 of the operator compartment 16. The housing recess 140 may have a curvilinear shape.
As shown in Fig. 14, a chamfered surface 141 extends around the outer periphery of
the housing recess 140 in this embodiment, between the housing recess 140 and the
control element area 134. The chamfered surface 141 may allow an operator increased
space for reaching a control element 142 that is mounted to the second housing 130
and extends outwardly from the housing recess 140. The control element 142 may have
an enlarged tip portion 142A distal from the base portion 144 compared to the control
element 142 described above for Fig. 9 but may otherwise be the same or similar to
the control element 142 described above for Fig. 9 and will not be described in detail
herein.
[0097] An elongate grip member 150 according to this embodiment may be the same or similar
to the grip member 150 described above for Fig. 9, but the grip member 150 of Fig.
14 may include an additional control element 151 located thereon, such as a horn button.
[0098] Referring now to Figs. 15-31, Fig. 15 illustrates a materials handling vehicle 310
constructed in accordance with embodiments. In the illustrated embodiment, the vehicle
310 comprises a stockpicker, but could be another type of materials handing vehicle.
The vehicle 310 includes a power unit 312, a platform assembly 314 including an operator
compartment 316, and a load handling assembly 318. The power unit 312 includes a power
source, such as a battery unit 320. The vehicle 310 includes a plurality of wheels
322 on which the vehicle 310 travels (one or more additional wheels are located underneath
the power unit 312 but are not shown in Fig. 15). The load handling assembly 318 comprises
a mast assembly 330 coupled to the power unit 312 on which the platform assembly 314
moves vertically. A fork structure 332 comprises a pair of forks 332A, 332B which
are coupled to the platform assembly 314 or mast assembly 330 for movement with the
platform assembly 314. The mast assembly 330 comprises one or more mast sections.
Mast sections may also be referred to herein as mast weldments. The exemplary mast
assembly 330 illustrated in Fig. 15 is a three-stage mast assembly comprising first,
second and third mast sections or weldments 330A-330C, see also Fig. 19A. The platform
assembly 314 is attached to and moves relative to the third mast section or weldment
330C via a carriage 314B with rollers (only studs on which the rollers are mounted
are illustrated in Fig. 17), see Fig. 17, which carriage 314B forms part of the platform
assembly 314 and is lifted via a primary lift ram/cylinder assembly 326 mounted to
the third section. The second and third mast sections or weldments 330B and 330C move
relative to the first, stationary mast section or weldment 330A. One or more hydraulic
secondary lift ram/cylinder assemblies are fixed at their cylinder bases to the power
unit 312 or first mast section 330A and the rams are fixed to the second mast section
330B. A chain is coupled at a first end to a cylinder of each secondary lift ram/cylinder
assembly or to the first mast section, extends over a corresponding pulley on the
second mast section 330B and is fixed at its second end to the third mast section
330C. As each ram extends, the ram causes the second mast section 330B to move relative
to the first mast section 330A and also causes the third mast section 330C to move
via the chain relative to the first and second mast sections 330A and 330B. As the
second mast section 330B is raised, the third mast section 330C raises twice the distance.
The mast assembly 300 is illustrated in its fully retracted home position in Figs.
15 and 25, and in its fully extended state in Fig. 26. The platform assembly 314 is
positioned in its fully retracted state in Fig. 15. When the second and third mast
sections 330B and 330C are fully retracted and the platform assembly 314 is fully
retracted, an upper portion 331A-331C of each of the first, second and third mast
sections 330A-330C extends above an upper section 314A of the platform assembly 314,
see Fig. 15. Further, when the second and third mast sections 330B and 330C are fully
retracted and the platform assembly 314 is fully retracted, the upper portion 331A-331C
of each of the first, second and third mast sections 330A-330C extends above an upper
part 362A of first operator control assembly 362 and/or an upper part 364A of second
operator control assembly 364, see Figs. 15 and 20.
[0099] The operator compartment 316 includes a floor surface 340 upon which an operator
stands while operating the vehicle 310 from an operator station 342 located in the
operator compartment 316. An operator presence sensor 344 in the form of a pressure
switch that senses an operator's foot is provided in the floor surface 340. The floor
surface 340 may also be referred to herein as the floorboard. According to embodiments,
one or more functions of the vehicle, such as traveling movement, raising/lowering
the load handling assembly 318, etc. may be disabled unless the operator presence
sensor indicates the presence of the operator in the operator compartment 316. First
and second side restraints 346, 348 are provided at opposed left and right sides LS',
RS' of the operator compartment 316, the left and right sides LS', RS' being spaced
apart from one another in a lateral direction L
D' that is perpendicular to a longitudinal axis L
A' of the vehicle 310. A support wall 324 is connected to the floorboard and positioned
adjacent to and spaced from the mast assembly 330, further defining the operator compartment
316 of the platform assembly 314. The support wall 324 may also be referred to herein
as an "inner support wall."
[0100] The operator station 342 may include one or more bins 350 in which the operator can
store items. The bins 350 may be positioned anywhere in the operator station 342 and
may be movable as desired. The operator station 342 may further comprise a first support
structure 352 and a second support structure 354 spaced apart from each other in the
lateral direction L
D', see Fig. 15. The first and second support structures 352, 354 are separated by
a recessed portion 356 of the vehicle 310 that defines an open area between the first
and second support structures 352, 354. In the illustrated embodiment, the open area
extends to just above one of the bins 350 but could extend further towards the floor
surface 340 if the bin 350 below the open area is not provided.
[0101] An operator control system 360 is provided in the operator station 342. The operator
uses the operator control system 360 to drive the vehicle 310 and to control one or
more other vehicle functions. With reference to Fig. 15, the operator control system
360 comprises the first operator control assembly 362 associated with the first support
structure 352 and the second operator control assembly 364 associated with the second
support structure 354. In the illustrated embodiment, the first operator control assembly
362 is provided to control steering of the vehicle 310 and optionally to control additional
vehicle functions, and the second operator control assembly 364 is provided to control
load handling assembly lift and lower functions, direction and speed control and optionally
other vehicle functions. As further illustrated in the embodiment, the first operator
control assembly 362 and second operator control assembly 364 are coupled to the support
wall 324 and positioned to allow for operation by an operator located within the operator
compartment 316.
[0102] A non-horizontal viewing window 402, which may also be referred to as a "mid window"
or "first viewing window," is provided in the support wall 324 comprising an upper
end 402A and lower end 402B, wherein the lower end 402B extends or is positioned below
a lower part 362B of the first operator control assembly 362 and/or a lower part 364B
of the second operator control assembly 364 to maximize downward viewing by the operator,
see Figs. 15 and 20. The non-horizontal viewing window 402 may be positioned between
the first operator control assembly 362 and second operator control assembly 364 in
the illustrated embodiment. The viewing window upper end 402A may be below, on level
with, or extend above the upper part 362A of first operator control assembly 362 and/or
the upper part 364A of second operator control assembly 364.
[0103] The term non-horizontal means that the viewing window 402 has a vertical dimension
greater than a horizontal dimension. In some embodiments, the non-horizontal viewing
window 402 has a vertical dimension Hv between 18 inches and 22 inches, see Fig. 20.
In the illustrated embodiments, the viewing window 402 appears as a generally rectangular
or a tapered generally trapezoidal shape and its corners, sides and edges may vary
provided that the shape of viewing window 402 is defined to maximize downward visibility.
Thus, the sides and corners of window 402 may be linear or curvilinear to achieve
this purpose. It is also contemplated that the viewing window 402 may comprise any
other shape such as a circle, oval, square, triangle, etc.
[0104] In the embodiments shown in Fig. 15-31, the width Wv of the non-horizontal viewing
window 402 may be equal to between 30% to 50% of the overall width Wsw of the support
wall 324, see Fig. 20. The non-horizontal viewing window 402 is illustrated in Figs.
15 and 20 as centered on the support wall 324 between generally the left side LS'
and right side RS' of the operator compartment 316, but may be positioned horizontally
at any location in the support wall 324 as required to maximize downward viewing by
the operator between the first operator control assembly 362 and the second operator
control assembly 364, and between the first support structure 352 and the second support
structure 354.
[0105] In the embodiment of Fig. 20, the non-horizontal viewing window 402 may comprise
a clear pane 406 of suitable material, such as clear polymer, glass, mesh-reinforced
glass or, as in the embodiment of Fig. 22, a see-through screen 408.
[0106] The support wall 324 and the non-horizontal viewing window 402 are in a generally
vertical orientation in the platform assembly 314. The non-horizontal viewing window
402 is shown in Figs. 21 and 23 positioned in a first vertical plane Pv. By generally
vertical orientation, it is appreciated that "vertical" is relative to the floor surface
340 of the vehicle which lies on the generally horizontal plane of Hp' when the vehicle
is located on level ground.
[0107] While not shown in the Figures, it can be appreciated in some embodiments that the
non-horizontal viewing window 402 and adjacent portions of the support wall 324 may
also be angled away from the mast assembly 330 at the viewing window lower end 402B
and protrude slightly into the recessed portion 356 of the operator compartment 316
to enhance the ease of viewing through the non-horizontal viewing window 402 particularly
for embodiments that include a see-through screen 408 as in Fig. 22. Below lower end
402B of non-horizontal viewing window 402, the support wall 324 may extend back towards
the first vertical plane Pv so that the recessed portion 356 below the non-horizontal
viewing window 402 remains open for use by the operator.
[0108] Figs. 19A and 19B illustrate the relationship between the non-horizontal viewing
window 402, the support wall 324, and the mast assembly 330. An inner edge 430 of
the third mast section or mast weldment 330C, i.e., the edge of the mast assembly
330 closest to the viewing window 402, defines an inner mast assembly vertical plane
P
M, see Figs. 19A and 19B. An outer surface 404 of the non-horizontal viewing window
402 is located a small distance Dv from the inner mast assembly vertical plane P
M, which distance Dv may be between 0.5 inches to 2 inches.
[0109] With reference to Figs. 25 and 26, the operator of the materials handling vehicle
310 may see, without bending, through the non-horizontal viewing window 402 along
view lines F
A and F
B, enabling the operator to view forward areas left, right and along longitudinal axis
L
A' of vehicle 310. View line F
B extends from the operator's eye through the lower end 402B of non-horizontal viewing
window 402, and view line F
A extends from the operator's eye through the upper end 402A of non-horizontal viewing
window 402. It is noted that the location of the view lines F
A and F
B may change based on operator height and position. Depending on the elevation of the
platform assembly 314, the view area between view lines F
A and F
B may be steeper and narrower or less steep and broader. At some elevations the view
area may advantageously include the power unit 312, such as left and right corners
312A and 312B of the power unit 312, as illustrated from the operator's perspective
in Fig. 24. This allows the operator to have increased/enhanced viewing of the power
unit 312 and surrounding area when elevated on the platform assembly 314. The view
in Fig. 24 may be from the operator's point of view while standing without leaning
with the platform assembly 314 in the elevated position of Fig. 25 but may also be
from an operator's point of view with the platform assembly 314 in the elevated position
of Fig. 26 if the operator leans forward so as to be close to the viewing window 402.
[0110] As illustrated in the embodiment of Fig. 15, the materials handling vehicle 310 may
include a second viewing window 422 located above the non-horizontal viewing window
402. Referring to Figs. 20-23, an inner surface 422A of the second viewing window
422 is positioned in a second generally vertical plane Po, that represents the inner
face closest to the operator of the second viewing window 422. An inner surface 1402A
of the first viewing window 402 is positioned in the first vertical plane Pv. Second
vertical plane Po may be spaced from the first vertical plane Pv, wherein the inner
surface 1402A positioned in the first vertical plane Pv represents the inner face
closest to the operator of the first, non-horizontal viewing window 402. In the illustrated
embodiment, the first vertical plane Pv is located closer to the mast assembly 330
than the second vertical plane Po. Figs. 20-23 illustrate that the space or distance
Do between the first vertical plane Pv and second vertical plane Po may vary depending
on whether the second viewing window 422 comprises a second transparent pane 426 or
a second see-through screen 428 and the configuration thereof, and embodiments include
a space Do of from 0.1 inches to 3 inches (transparent pane), and from 0.25 inches
to 2.5 inches (screen). It is also contemplated that the first vertical plane Pv and
the second vertical plane Po may comprise the same plane. The second viewing window
422 may comprise a clear pane 426 of suitable material, see Figs. 20 and 21, such
as clear polymer, glass, mesh-reinforced glass or, as in the embodiment of Figs. 22
and 23, a see-through screen 428. It is also contemplated that the first viewing window
402 may comprise a polymeric, e.g., plexiglass, pane and the second viewing window
422 may comprise a glass pane.
[0111] Referring again to Figs. 25 and 26, the operator of materials handling vehicle 310
may see through a lower portion of the second viewing window 422 downward along view
line Fc and forward to the horizon and above, and left, right and along longitudinal
axis L
A' of vehicle 310. The area viewed along view line Fcfrom the same operator position
as described above for view lines F
A and F
B, begins further outward from the materials handling vehicle 310 along longitudinal
axis L
A' than the area viewed through the non-horizontal viewing window 402, as illustrated
in Figs. 25 and 26.
[0112] As shown in Fig. 15, the upper section 314A of the platform assembly 314 additionally
includes an overhead guard assembly 500 that is positioned over the operator compartment
316. The overhead guard assembly 500 comprises a base frame 502 that includes first
and second side bar members 502A, 502B, a front bar member 502C, and a back bar member
502D, see also Figs. 16 and 17. The bar members 502A, 502B, 502C, 502D may be formed
separately and joined together, e.g., by welding or bolting, or one or more of the
bar members 502A, 502B, 502C, 502D may be formed integrally together as a single structure.
According to one exemplary embodiment, the first, second, and front bar members 502A,
502B, 502C are integrally formed as a single structure that is joined to the back
bar member 502D. One or more spanning members (not shown) may span between the first
and second side bar members 502A, 502B or the front and back bar members 502C, 502D
to separate a central opening 502E defined by the base frame 502 into smaller sections.
According to an alternate embodiment, a transparent window (not shown) may be used
in place of the spanning members to allow an operator in the operator compartment
316 who is looking up to see through the central opening 502E.
[0113] The overhead guard assembly 500 may further comprise first and second extension members
504A, 504B that extend laterally from the respective first and second side bar members
502A, 502B. The extension members 504A, 504B effect an increase in a lateral width
L
WG of the overhead guard assembly 500, see Fig. 16. Front and back corner portions 506A
1, 506A
2, 506B
1, 506B
2 of the first and second extension members 504A, 504B provide the overhead guard assembly
500 with angled surfaces at its corners. Hence, when the vehicle 310 is traveling
in a power unit-first or forks-first direction, contact between the first and second
extension members 504A, 504B and objects, such as racks, pallets, etc., would not
be at a 90 degree angle, which may reduce or prevent damage to the overhead guard
assembly 500 and/or other parts of the platform assembly 314, i.e., since the objects
may deflect off of the angled surfaces defined by the front or back corner portions
506A
1, 506A
2, 506B
1, 506B
2 instead of contacting non-angled surfaces at 90 degrees.
[0114] First and second extension members 504A, 504B having different lateral widths according
to additional embodiments are shown in Figs. 17A-17C. In accordance with an aspect,
the first and second extension members 504A, 504B selected for use on a particular
vehicle 310 may be chosen based on a lateral width L
WF of the floor surface 340 (see Fig. 15) of the operator compartment 316, e.g., the
lateral width L
WG of the overhead guard assembly 500, including the first and second extension members
504A, 504B, may be generally equal to the lateral width L
WF of the floor surface 340. According to another embodiment, the lateral width L
WG of the overhead guard assembly 500, including the first and second extension members
504A, 504B, may be greater than the lateral width L
WF of the floor surface 340. The first and second extension members 504A, 504B shown
in Figs. 17A-17C also have the angled front and back corner portions 506A
1, 506A
2, 506B
1, 506B
2, and the first and second extension members 504A, 504B shown in Figs. 17A-17B additionally
include spanning members 508 that separate openings defined in an interior portion
of the first and second extension members 504A, 504B into smaller sections.
[0115] Referring now to Figs. 27-30, additional embodiments of a materials handling vehicle
510 are shown. As shown in Fig. 27, the vehicle 510 may include a power unit 512,
a platform assembly 514, and a load handling assembly 518 with a mast assembly 530,
which may be substantially similar to the vehicles 10 and 310 described herein. An
operator compartment 516 may be at least partially defined by an inner support wall
524 including an inner viewing window 402, a floorboard 540 that defines a generally
horizontal floor surface of the vehicle 510, and an outer support wall 640, in which
the outer support wall 640 is connected to the floorboard 540 and opposite the inner
support wall 524. First and second side restraints 546, 548 are provided on either
side of the vehicle 510. As shown in Fig. 27, a first operator control system 560
(also referred to herein as an inner operator control system) is coupled to the inner
support wall 524 and may comprise a first inner operator control assembly 562 and
a second inner operator control assembly 564. As shown in Figs. 28 and 30, a second
operator control system 660 (also referred to herein as an outer operator control
system) is coupled to the outer support wall 640 and may comprise a first outer operator
control assembly 662 and a second outer operator control assembly 664. The first and
second operator control systems 560 and 660 are positioned to allow for operation
by an operator located within an operator compartment 516 of the vehicle 510, as described
herein in more detail.
[0116] In the embodiments of Figs. 27-30 at least one outer viewing window 442 or 444 is
positioned in the outer support wall 640. First outer viewing window 442 and second
outer viewing window 444 are located below the operator control assemblies 662, 664
of the outer operator control system 660 and spaced apart laterally a distance D
P, see Fig. 28. First outer viewing window 442 has an upper end 442A and a lower end
442B, and second outer viewing window 444 has an upper end 444A and a lower end 444B.
Each of the first and second outer viewing windows 442, 444 may comprise a clear pane
446 of suitable material, such as clear polymer, glass, mesh-reinforced glass, as
illustrated in Fig. 28, or a see-through screen 448 as illustrated in Fig. 30.
[0117] Illustrated in Figs. 27, 28A and 28B, a fork carriage assembly 470 is coupled to
the outer support wall 640 and includes first and second forks 470A and 470B and a
movable fork carriage 471 to which the forks 470A and 470B are coupled for movement
with the movable fork carriage 471. A ram/cylinder assembly 474 is provided for moving
the fork carriage 471 and forks 470A and 470B vertically relative to the outer support
wall 640. The fork carriage 471 includes rollers 472 that move within tracks of rails
642 forming part of the outer support wall 640, see Fig. 28A. The cylinder 474A of
the ram/cylinder assembly 474 is fixed to a base member 644 of the outer support wall
640, see Figs. 28 and 29. The ram 474B of the ram/cylinder assembly 474 may be fixed
to the fork carriage assembly 470 such that movement of the ram 474B effects movement
of the fork carriage assembly 470. Alternatively, a chain (not shown) may be fixed
at one end to the cylinder 474A and at a second end to the fork carriage assembly
470. A roller may be fixed to an end of the ram 474B which roller engages the chain
to effect lift of the fork carriage assembly 470. When the fork carriage assembly
470 is raised to an upper position, see Fig. 28B, the forks 470A and 470B are positioned
such that an operator can view downwardly below the forks through the first and second
outer viewing windows 442 and 444.
[0118] With reference to Fig. 31, the operator of materials handling vehicle 510 may see,
without bending, through outer viewing windows 442, 444 along view lines R
A and R
B, enabling the operator to view rearward areas, also referred to as "fork facing areas,"
to the left, right and rearward along the longitudinal axis L
A' of vehicle 510. View lines R
B extend from the operator's eye through the lower ends 442B and 444B of viewing windows
442, 444, respectively; and view lines R
A extend from the operator's eye through the upper end 442A, 444A of viewing windows
442, 444. It is noted that the location of the view lines R
A and R
B may change based on operator height and position. Depending on the elevation of the
platform assembly 514, the view area between view lines R
A and R
B may be steeper and narrower or less steep and broader as illustrated from the operator's
perspective in Fig. 31.
[0119] With reference to Figs. 32-38, the inner and outer operator control systems 560,
660 of the materials handling vehicle 510 of Figs. 27-31 will be described in more
detail (the side restraints 546, 548 are removed to illustrate other aspects in detail).
While operating the vehicle 510 shown in Fig. 32, the operator stands on the floorboard
540 in the operator compartment 516 at one of a first operator station 542 (also referred
to herein as an inner operator station) or a second operator station 543 (also referred
to herein as an outer operator station). An operator presence sensor 544, e.g., a
pressure switch, is provided in the floorboard 540 and senses an operator's foot.
As described herein, one or more functions of the vehicle may be disabled unless the
operator presence sensor 544 indicates the presence of the operator in the operator
compartment 516.
[0120] With continued reference to Fig. 32, the inner operator station 542 may be substantially
similar to the operator station 42, 342 described herein and may comprise a first
support structure 552 and a second support structure 554. The first and second support
structures 552, 554 may be spaced apart from each other in a lateral direction L
D" that is perpendicular to a longitudinal axis L
A" of the vehicle 510. The first and second support structures 552, 554 are separated
by a recessed portion 556 of the vehicle 510 that defines an open area extending downward
from upper surfaces (not labeled) of the first and second support structures 552,
554 toward the floorboard 540.
[0121] The inner operator control system 560 comprises the first and second operator control
assemblies 562, 564, which are provided at the inner operator station 542 and are
coupled to the inner support wall 524 to allow for operation by an operator located
at the inner operator station 542, e.g., by an operator facing toward the inner support
wall 524. The first and second operator control assemblies 562, 564 are used to drive
the vehicle 510 and to control one or more other vehicle functions, as described in
detail herein. In the illustrated embodiment, the first operator control assembly
562 is provided to control steering of the vehicle 510 and optionally to control additional
vehicle functions, and the second operator control assembly 564 is provided to control
a traveling direction of the vehicle 510, load handling assembly lift and lower functions,
and optionally other vehicle functions, as described in greater detail herein above
in relation to first and second operator control assemblies 62, 64.
[0122] With reference to Figs. 33 and 36, the first operator control assembly 562 may be
substantially similar to the first operator control assembly 62, as described herein.
The first operator control assembly 562 is associated with the first support structure
552 and comprises a first housing 566 that may be separate from, but mounted to, the
first support structure 552 via fasteners, adhesive, etc. In other examples, the first
housing 566 may be integral with a portion of the first support structure 552 (see
Fig. 2A). The first operator control assembly 562 further comprises a steering assembly
580. As described in detail herein with respect to the first operator control assembly
62 and the steering assembly 80, the steering assembly 580 is movable between a first
position (shown in Fig. 33) and a second position (shown in Fig. 36) and may be locked
in these two positions via a lock assembly (not labeled).
[0123] With reference to Fig. 33, the second operator control assembly 564 may be substantially
similar to the second operator control assembly 64, as described herein. The second
operator control assembly 564 is associated with the second support structure 554
and comprises a second housing 582 that may be separate from, but mounted to, the
second support structure 554 via fasteners, adhesive, etc. In other examples, the
second housing 582 may be integral with the second support structure 554 (see Fig.
2A). The second operator control assembly 564 comprises a housing recess 646 that
extends downwardly in a direction toward the floorboard 540 of the operator compartment
516 (see Fig. 32); a control element 648 mounted to the second housing 582 and extends
outwardly from the housing recess 646; and an elongate grip member 650 mounted to
the second housing 582 and extending over the housing recess 646. The control element
648 and elongate grip member 650 may be substantially similar to the control element
142 and elongate grip member 150 of the second operator control assembly 64, and one
or both of the control element 648 and the elongate grip member 650 may be removed
and replaced with a replacement control element and/or replacement grip member (not
shown) having different dimensions and/or different configurations than the original
(replaced) control element 648 and/or elongate grip member 650 (see Figs. 10A-11F).
[0124] Similar to the first and second operator control assemblies 62, 64, the first and
second operator control assemblies 562, 564 may optionally be mounted to the first
and second support structures 552, 554 to allow the first and/or second operator control
assemblies 562, 564 to be positioned in multiple respective positions relative to
the first and second support structures 552, 554. With reference to Fig. 34, the first
and second operator control assemblies 562, 564 may comprise respective first and
second fixture structures 680, 682, e.g., mounting plates 684, 704, which may be substantially
similar to the mounting plates 184, 204 associated with the first and second operator
control assemblies 62, 64, respectively. As described herein, the mounting plates
684, 704 may support the first and second operator control assemblies 562, 564 in
respective first and second angular orientations relative to the first and second
support structures 552, 554 (see Figs. 12A-13D). Also as described herein, the first
and second support structures 552, 554 may be positioned closer to one another in
a narrow width vehicle and further away from one another in a wide width vehicle.
The angular orientation of one or both of the first and second operator control assemblies
562, 564 may be selected to provide preferred ergonomic hand positioning for a narrower
width vehicle or a wider width vehicle.
[0125] Alternatively, or in addition, a vertical position of the first and second operator
control assemblies 562, 564 relative to the floorboard 540 (e.g., in a direction substantially
parallel to the vertical plane V
P shown in Fig. 1) may be adjustable to achieve ergonomic positioning for operators
of varying dimension (e.g., height, arm length, etc.) and to accommodate operator
preference. With reference first to Fig. 33, the first support structure 552 may comprise
a fixed housing portion 552A and a movable housing portion 552B that is movable relative
to the fixed housing portion 552A. The second support structure 554 may similarly
comprise a fixed housing portion 554A and a movable housing portion 554B that is movable
relative to the fixed housing portion 554A. As described herein in more detail, the
movable housing portions 552B, 554B may be positioned to telescope over the respective
fixed housing portions 552A, 554A as the vertical position of the first and second
operator control assemblies 562, 564 is adjusted.
[0126] The first operator control assembly 562 and movable housing portion 552B in Fig.
33 are shown in a lowered position with solid lines, and an outline of the first operator
control assembly 562 and movable housing portion 552B in a raised position is indicated
with dashed lines. The second operator control assembly 564 and movable housing portion
554B are shown in a raised position with solid lines, and an outline of the second
operator control assembly 564 and movable housing portion 554B in a lowered position
is indicated with dashed lines. As described herein in more detail, the first operator
control assembly 562 may be fixedly coupled to the movable housing portion 552B, such
that the first operator control assembly 562 and movable housing portion 552B move
together, and the second operator control assembly 564 may similarly be fixedly coupled
to the movable housing portion 554B, such that the second operator control assembly
564 and movable housing portion 554B move together. The first and second operator
control assemblies 562, 564 may each be movable continuously between respective raise
and lowered positions to allow the first and second operator control assemblies 562,
564 to be arranged at a desired vertical position. The first operator control assembly
562 and movable housing portion 552B, when moving between the lowered position and
the raised position, may be movable by a distance D
1. The second operator control assembly 564 and movable housing portion 554B, when
moving between the lowered position and the raised position, may similarly be movable
by a distance D
2. In some examples, the distances D
1 and D
2 may be between about 0.1 to about four inches.
[0127] With reference to Figs. 36-38, a first vertical adjustment assembly 800 for selectively
supporting the first operator control assembly 562 at a plurality of vertical positions
is illustrated. The first vertical adjustment assembly 800 is coupled to the first
operator control assembly 562 to provide for movement of the first operator control
assembly 562 in a vertical direction indicated by arrow A relative to the floorboard
540 (see Fig. 32) and relative to the fixed housing portion 552A. The first vertical
adjustment assembly 800 may comprise a first mounting plate 802 that fixedly couples
the first vertical adjustment assembly 800 to the inner support wall 524. For example,
the first mounting plate 802 may comprise a plurality of openings 804 and a plurality
of fasteners 806 such as bolts, which extend through the openings 804 and are received
in corresponding openings (not shown) formed in the inner support wall 524 to attach
the first mounting plate 802 to the inner support wall 524. In other examples, the
first mounting plate 802 may be welded or otherwise attached to the inner support
wall 524.
[0128] The first vertical adjustment assembly 800 may further comprise a rail member 808
that is coupled to the first mounting plate 802. For example, a plurality of fasteners
812 such as bolts may extend through a plurality of openings 814 formed in the first
mounting plate 802 and may be received in corresponding openings 810 formed in the
rail member 808 to attach the rail member 808 to the first mounting plate 802. In
other examples, the rail member 808 may be welded or otherwise attached to the first
mounting plate 802.
[0129] With continued reference to Figs. 36-38, the fixture structure 680, i.e., the mounting
plate 684, of the first operator control assembly 562 may be coupled to the first
mounting plate 802 and to the rail member 808 via a carriage assembly 816. For example,
the mounting plate 684 may comprise a plurality of openings 820, and a plurality of
fasteners 818 may extend through the openings 820 and may be received in corresponding
openings 822 formed in the carriage assembly 816 to couple the mounting plate 684
to the carriage assembly 816. The carriage assembly 816 may be movably coupled to
the rail member 808 via a plurality of linear bearing blocks 824. The linear bearing
blocks 824 may be coupled to the carriage assembly 816 via a plurality of fasteners
826, which extend through a plurality of openings 828 formed in the carriage assembly
816 and are received in corresponding opening 830 formed in the linear bearing blocks
824. As described herein in more detail, the linear bearing blocks 824 slide vertically
along the rail member 808 to effect vertical movement of the carriage assembly 816.
[0130] In the embodiment shown, the rail member 808 comprises first and second rails 808A,
808B, and the carriage assembly 816 comprises four linear bearing blocks 824. A first
pair of the linear bearing blocks 824 engage the first rail 808A, and a second pair
of the linear bearing blocks 824 engage the second rail 808B. In other examples (not
shown) the rail member 808 may comprise a single rail or three or more rails, and
the number of linear bearing blocks 824 may be varied as desired to achieve a stable
coupling between the carriage assembly 816 and the rail member 808. Cables, wiring,
etc. (not shown) extending between the first operator control assembly 562 and the
vehicle electronic processor or controller provide control signals to the electronic
processor/controller to control respective functions of the vehicle 510. The carriage
assembly 816 may optionally comprise one or more cable guides 878 that secure the
cables and prevent them from interfering with vertical movement of the first operator
control assembly 562.
[0131] The first mounting plate 802 may be coupled to the fixed housing portion 552A of
the first support structure 552. For example, as shown in Figs. 36-38, the first mounting
plate 802 may comprise one or more extensions 864 with openings 866 formed therein.
Fasteners 868 extend through spacers 870 and are received in the openings 866. The
spacers 870 surround the fasteners 868, and upon receipt of the fasteners 868 in the
openings 866, the spacers 870 may extend outward from an inner face (not labeled)
of the first mounting plate 802, i.e., the portion of the first mounting plate 802
facing toward the operator compartment 516. With reference to Fig. 34, in which an
outer face (not labeled) of the first mounting plate 802 (i.e., the portion of the
first mounting plate 802 facing away from the operator compartment 516) is visible,
the fixed housing portion 552A may comprise, for example, brackets (not labeled) that
engage the first mounting plate 802 (e.g., the spacers 870 extending outward from
the inner face) to secure the fixed housing portion 552A to the first mounting plate
802.
[0132] The carriage assembly 816 may similarly be coupled to the movable housing portion
552B of the first support structure 552. For example, as shown in Figs. 36-38, the
carriage assembly 816 may comprise one or more threaded bores (not visible) formed
in an inner face and/or one or more side faces (not labeled), which receive fasteners
872 (only one fastener 872 is visible in Fig. 36). Each fastener 872 comprises a respective
spacer 874, 876 that surrounds the fastener 872, and upon receipt of the fasteners
872 in the threaded bores, the spacers 874, 876 may extend outward from the inner
and/or side face(s) of the carriage assembly 816. The movable housing portion 552B
may comprise brackets (not labeled) that engage the carriage assembly 816 (e.g., the
spacers 874, 876 extending outward from the inner and/or one or more side faces) to
secure the movable housing portion 552B to the carriage assembly 816 (the spacers
874 extending outward from the side faces of the carriage assembly 816 may be seen
in Fig. 34).
[0133] As best seen in Figs. 37 and 38, the first vertical adjustment assembly 800 further
comprises a locking gas spring 832 that controls the vertical position and movement
of the carriage assembly 816 and the mounting plate 684 (and thus the first operator
control assembly 562) relative to the first mounting plate 802 and the rail member
808. The locking gas spring 832 may comprise a rod 834 and a cylinder 836. One end
of the cylinder 836 comprises a fitting 838 that engages a protrusion 840 formed on
the mounting plate 684. A snap ring (not labeled) may be used to secure the fitting
838 to the protrusion 840.
[0134] A receiver 844 may be coupled to the first mounting plate 802 by, for example, a
fastener 848 that extends through an opening 852 and is received in an internally
threaded bore of a standoff 854. An opposing end of the rod 834, which may comprise
a release valve 842, is inserted into an opening 844A formed in the receiver 844.
The receiver 844 comprises a slot 844B that receives a cam 850. An opening 844C is
formed through the portion of the receiver 844 comprising the slot 844B, and a pin
846 extends through the opening 844C and through an opening 850A formed in the cam
850 to pivotably secure the cam 850 to the receiver 844. A lower portion of the opening
844A may be in communication with the slot 844B, such that when the rod 834 of the
locking gas spring 832 is inserted into the opening 844A, an extension 850C of the
cam 850 is positioned adjacent to, or in contact with, the release valve 842.
[0135] A lever 860 is positioned below the locking gas spring 832 and is coupled to the
receiver 844 and to the cam 850 to operate the release valve 842 of the locking gas
spring 832. The lever 860 comprises a fixed end 860-1 and a free end 860-2. In the
embodiment shown, the standoff 854 may extend through an opening 844D formed in the
receiver 844 and through an opening 860A formed in the fixed end 860-1 of the lever
860. A snap ring (not labeled) may be used to secure the fixed end 860-1 of the lever
860 to the receiver 844 and pivotably couple the lever 860 to the receiver 844. The
fixed end 860-1 of the lever 860 comprises a protrusion 862 that is received in an
opening 850B formed in the cam 850. The standoff 854 maintains the necessary spacing
to prevent contact between the protrusion 862 and the first mounting plate 802.
[0136] With reference to Figs. 34-38, operation of the first vertical adjustment assembly
800 will be described in detail. As shown in Figs. 34 and 36, the free end 860-2 of
the lever 860 is in a rest or first position, and the first operator control assembly
562 is in a lowered position, i.e., a first vertical position. An operator applies
an upward force to the free end 860-2 of the lever 860, as indicated by arrow B, to
move the free end 860-2 of the lever 860 from the first position to a raised or second
position shown in Figs. 35 and 37. The fixed housing portion 552A may comprise a slot
553 that accommodates movement of the lever 860.
[0137] Movement of the free end 860-2 of the lever 860 from the first to the second position
causes the fixed end 860-1 of the lever 860 to rotate about an axis 880 shown in Fig.
37. Engagement between the cam 850 and the protrusion 862 formed on the lever 860
causes the cam 850 to pivot, such that the extension 850C of the cam 850 moves upward
and actuates, e.g., depresses, the release valve 842. Actuation of the release valve
842 unlocks the locking gas spring 832 and permits vertical movement of the first
operator control assembly 562 in the direction indicated by arrow A. The mounting
plate 684 moves upward with the cylinder 836 of the locking gas spring 832 due to
the engagement between the fitting 838 and the protrusion 840 (a portion of the cylinder
836 is visible in Figs. 34 and 35). The carriage assembly 816, which is coupled to
the mounting plate 684, slides upward along the rail member 808 via the linear bearing
blocks 824, and the movable housing portion 552B, which is coupled to the carriage
assembly 816, telescopes upward along the fixed housing portion 552A. Thus, the first
operator control assembly 562 and the movable housing portion 552B (via the carriage
assembly 816 and the mounting plate 684) move from the first vertical position shown
in Figs. 34 and 36 toward a second vertical position, i.e., the raised position shown
in Figs. 35 and 37.
[0138] In some examples, the locking gas spring 832 may be configured such that the cylinder
836 immediately moves upward (i.e., away from the release valve 842) upon actuation
of the release valve 842, without the need for the application of an additional force.
In other examples, the locking gas spring 832 may be configured such that an additional
upward force is needed to effect upward movement, e.g., the operator may actuate the
lever 860 with a foot or with one hand and may use the other hand to exert an additional
upward force on the first operator control assembly, e.g., the first housing 566,
to guide the first operator control assembly 562 to the desired position. In further
examples, the first vertical adjustment assembly 800 may optionally comprise one or
more additional structures, e.g., a cable assembly (not shown) extending between the
lever 860 and the locking gas spring 832, that actuate the release valve 842 to unlock
the locking gas spring 832, and in some particular examples, the lever 860 may be
positioned at a different location on the first support structure 552 or the first
operator control assembly 562 (e.g., above all or part of the locking gas spring 832).
[0139] Following placement of the first operator control assembly 562 at the desired vertical
position, the operator releases the free end 860-2 of the lever 860. The free end
860-2 of the lever 860 returns to the first position, which disengages the extension
850C of the cam 850 from the release valve 842 and causes the locking gas spring 832
to lock, thereby fixing the first operator control assembly 562 in place.
[0140] To lower the first operator control assembly 562, the operator moves the free end
860-2 of the lever 860 from the first position to the second position by applying
an upward force in the direction indicated by arrow B with a foot or one hand, which
depresses the release valve 842 and unlocks the locking gas spring 832. The operator
then applies a downward force to the first operator control assembly 562, e.g., to
the first housing 566, with the other hand to cause a downward movement of the first
operator control assembly 562 in the direction indicated by arrow A. The mounting
plate 684 and carriage assembly 816 move downward with the cylinder 836 of the locking
gas spring 832, such that the first operator control assembly 562 and the movable
housing portion 552B move from a first vertical position (in this case, the raised
position shown in Fig. 35) toward a second vertical position (in this case, the lowered
position shown in Figs. 34 and 36). Following placement of the first operator control
assembly 562 at the desired vertical position, the operator releases the free end
860-2 of the lever 860, which causes the locking gas spring 832 to lock again, thereby
fixing the first operator control assembly 562 in place. The fixed housing portion
552A, the first mounting plate 802, and the rail member 808 remain stationary during
adjustment of the first operator control assembly 562.
[0141] With reference to Figs. 34 and 35, the second operator control assembly 564 may comprise
a second vertical adjustment assembly 900, which may be substantially similar to the
first vertical adjustment assembly 800. The second vertical adjustment assembly 900
is coupled to the second operator control assembly 564 to selectively support the
second operator control assembly 564 at a plurality of vertical positions and provide
for movement of the second operator control assembly 564 in the vertical direction
indicated by arrow A relative to the floorboard 540 (see Fig. 32) and relative to
the fixed housing portion 554A. The second vertical adjustment assembly 900 may comprise
a second mounting plate 902 that fixedly couples the second vertical adjustment assembly
900 to the inner support wall 524, as described with respect to the first mounting
plate 802. Although not visible, the second vertical adjustment assembly 900 may further
comprise a rail member and carriage assembly that are substantially similar to the
rail member 808 and carriage assembly 816, in which the rail member is attached to
the second mounting plate 902 and the carriage assembly is movably coupled to the
rail member via a plurality of linear bearing blocks. The fixture structure 682, i.e.,
the mounting plate 704, of the second operator control assembly 564 as shown in Figs.
34 and 35 may be coupled to the second mounting plate 902 and the rail member via
the carriage assembly.
[0142] Similar to the first mounting plate 802, the second mounting plate 902 may be coupled
to the fixed housing portion 554A of the second support structure 554. As shown in
Fig. 34, in which an outer face (not labeled) of the second mounting plate 902 is
visible, the second mounting plate 902 may comprise one or more extensions 964 that
receive fasteners with spacers (not visible), and the fixed housing portion 554A may
comprise brackets (not labeled) that engage the second mounting plate 902 (e.g., via
the spacers) to secure the fixed housing portion 554A to the second mounting plate
902.
[0143] Similar to the movable housing portion 552B of the first support structure 552, the
movable housing portion 554B of the second support structure 554 may be coupled to
the carriage assembly. For example, spacers 974 extending outward from side faces
of the carriage assembly are visible in Fig. 34, and the movable housing portion 554B
may comprise brackets (not labeled) that engage the carriage assembly (e.g., the spacers
974 extending outward from the side faces) to secure the movable housing portion 554B
to the carriage assembly. Although not visible, the movable housing portion 554B may
similarly comprise brackets that engage spaces extending outward from an inner face
of the carriage assembly.
[0144] With continued reference to Figs. 34 and 35, the second vertical adjustment assembly
900 may comprise a locking gas spring (only a cylinder 936 of the locking gas spring
is visible in Figs. 34 and 35), which may be substantially similar to the locking
gas spring 832 described herein. The locking spring may be coupled to the mounting
plate 704 of the second operator control assembly 564 to control the vertical position
and movement of the carriage assembly and the mounting plate 704 (and thus the second
operator control assembly 564) relative to the second mounting plate 902 and the rail
member. Although not visible, the second vertical adjustment assembly 900 may further
comprise a receiver and a cam, which may be substantially similar to the receiver
844 and cam 850 of the first vertical adjustment assembly 800.
[0145] A lever 960 is coupled to the receiver and to the cam to operate a release valve
of the locking gas spring and allow vertical movement of the second operator control
assembly 564. For example, to move the second operator control assembly 564 from a
first vertical position to a second vertical position (i.e., to raise and lower the
second operator control assembly 564), the operator applies an upward force with a
foot or with one hand to a free end 960-2 of the lever 960, as indicated by arrow
B, to move the free end 960-2 from a rest or first position shown in Fig. 34 to a
raised or second position shown in Fig. 35. The fixed housing portion 554A may comprise
a slot 555 that accommodates movement of the lever 960. As described herein in detail
with respect to the first vertical adjustment assembly 800, upward movement of the
free end 960-2 of the lever 960 depresses the release valve and unlocks the locking
gas spring. The second operator control assembly 564, along with the movable housing
portion 554B, may then be moved upward or downward in the direction indicated by arrow
A between the lowered position shown in Fig. 34 and the raised position shown in Fig.
35. Following placement of the second operator control assembly 564 at the desired
vertical position, the operator releases the free end 960-2 of the lever 960. The
free end 960-2 of the lever 960 returns to the first position, which causes the locking
gas spring to lock, thereby fixing the second operator control assembly 564 in place.
The fixed housing portion 554A, the second mounting plate 902, and the rail member
remain stationary during adjustment of the second operator control assembly 564.
[0146] The first and second operator control assemblies 562, 564 may be adjusted continuously
between the lowered and raised positions and may be placed at any desired vertical
position along a path of motion permitted by the first and second vertical adjustment
assemblies 800, 900 to achieve ergonomic positioning for operators of varying heights
and to accommodate operator preferences.
[0147] The vertical positions of the first and second operator control assemblies 562, 564
may be adjusted independently of each other. In addition, adjustment of the vertical
position of the first and second operator control assemblies 562, 564 may be used
in conjunction with one or more of the other adjustment features described herein,
including changing a position of the steering assembly 580 of the first operator control
assembly 562, replacing one or more elements of the second operator control assembly
564, and/or adjusting an angular orientation of the first and/or second operator control
assembly 562, 564 relative to the respective first and second support structures 552,
554. For example, when the steering assembly 580 is in the first position as shown
in Figs. 33-35, an operator may wish to place the first operator control assembly
562 at a lower vertical position, as compared to when the steering assembly 580 is
in the second position as shown in Fig. 36. The operator may also wish to adjust the
vertical position of the first and/or second operator control assemblies 562, 564
based on whether the first and second operator control assemblies are positioned at
the first or second angular orientation relative to their respective first and second
support structures 552, 554 (see Figs. 12A to 13D) and/or based on the dimension and/or
configuration of replaceable elements in the second operator control assembly 564.
All adjustments of the first and second operator control assemblies 562, 564 may be
performed independently of each other.
[0148] With reference to Figs. 28, 30, and 32, the outer operator control system 660 comprising
the first and second operator control assemblies 662, 664 is provided at the outer
operator station 543 and may be used as an alternative to the first operator control
system 560 to drive the vehicle 510 and to control one or more other vehicle functions.
For example, the first and second operator control assemblies 662, 664 are coupled
to the outer support wall 640 via one or more mounting brackets (not visible) and
are positioned to allow for operation by an operator located at the outer operator
station 543, e.g., by an operator facing toward the outer support wall 640 and the
fork carriage assembly 470 (see also Fig. 31).
[0149] The first and second operator control assemblies 662, 664 are spaced apart from each
other in the lateral direction L
D" and may be positioned, for example, on either side of the ram/cylinder assembly 474.
The first operator control assembly 662 may be substantially similar to the first
operator control assembly 62, 562 described herein and may comprise a first housing
666 and a steering assembly 780, which may be movable between a first position (shown
in Figs. 28, 30, and 32; see also Figs. 2, 3, and 5-7) and a second position (not
shown; see Figs. 4 and 8). The second operator control assembly 664 may be substantially
similar to the second operator control assembly 64, 564 described herein and may comprise
a second housing 668, a housing recess 746, a control element 748, and an elongate
grip member 750. One or both of the control elements 748 and the elongate grip member
750 may be removed and replaced with a replacement control element and/or replacement
grip member (not shown) having different dimensions and/or different configurations.
In addition, as described herein, the first and/or second operator control assemblies
662, 664 may optionally be mounted to the outer support wall 640 such that the first
and/or second operator control assemblies 662, 664 may be positioned at multiple angular
orientations and/or multiple vertical positions.
[0150] A dash 600 may extend between the first and second operator control assemblies 662,
664 and may define a horizontal support surface, which may be used as a work surface
by the operator. As best seen in Figs. 28 and 30, at least a portion of the first
and second operator control assemblies 662, 664 may be recessed with respect to an
upper surface 600A, 640A of the dash 600 and the outer support wall 640, respectively.
The first and second operator control assemblies 662, 664 may be positioned such that
a respective uppermost portion (e.g., the steering assembly 780 and the elongate grip
member 750) of the first and second operator control assemblies 662, 664 is flush
with, or recessed with respect to, the upper surfaces 600A, 640A of the dash 600 and
outer support wall 640. The positioning of the first and second operator control assemblies
662, 664 below the upper surfaces 600A, 640A of the dash 600 and outer support wall
640 allows objects, e.g., boxes, to slide across the upper surfaces 600A, 640A without
contacting the first and second operator control assemblies 662, 664. One or more
trays 602, 604 may be provided adjacent to the first and/or second operator control
assemblies 662, 664, which may be used by the operator to store items.
[0151] Representative embodiments of the present disclosure described above can be described
as follows:
A. An operator control system for a materials handling vehicle, the materials handling
vehicle comprising an operator station having a floorboard and a support structure,
the operator control system comprising:
an operator control assembly;
a fixture structure coupled to the support structure to selectively support the operator
control assembly in a plurality of angular orientations relative to the support structure;
and
a vertical adjustment assembly coupled to the operator control assembly to selectively
support the operator control assembly at a plurality of vertical positions relative
to the floorboard.
B. The operator control system according to paragraph A, wherein the fixture structure
comprises a mounting plate with one or more first openings and one more second openings
and a plurality of fasteners that couple a housing of the operator control assembly
to the support structure, wherein:
the operator control assembly is mounted at a first angular orientation relative to
the support structure when the fasteners are received in the one or more first openings
of the mounting plate; and
the operator control assembly is mounted at a second angular orientation relative
to the support structure when the fasteners are received in the one or more second
openings, the second angular orientation being different from the first angular orientation.
C. The operator control system according to paragraph B, wherein the operator control
assembly is rotated about an axis generally parallel to a longitudinal axis of the
materials handling vehicle when moved from the first angular orientation to a second
angular orientation.
D. The operator control system according to any of paragraphs A to C, wherein the
support structure comprises a fixed housing portion and a movable housing portion,
the movable housing portion being coupled to and movable with the operator control
assembly, wherein the movable housing portion is positioned to telescope over the
fixed housing portion.
E. The operator control system according to any of paragraphs A to D, wherein the
operator control assembly is continuously movable in a vertical direction between
a first vertical position and a second vertical position.
F. The operator control system according to any of paragraphs A to E, wherein the
vertical adjustment assembly comprises:
a mounting plate attached to a support wall of the materials handling vehicle;
a rail member attached to the mounting plate;
a carriage assembly movably coupled to the rail member, wherein the carriage assembly
is coupled to the fixture structure; and
a locking gas spring coupled to the fixture structure and the mounting plate to control
the vertical position of the operator control assembly.
G. An operator control system for a materials handling vehicle, the materials handling
vehicle comprising an operator station having a floorboard, a first support structure,
and a second support structure spaced apart from the first support structure in a
lateral direction, the operator control system comprising:
a first operator control assembly, a first fixture structure coupled to the first
support structure to selectively support the first operator control assembly in a
plurality of angular orientations relative to the first support structure, and a first
vertical adjustment assembly coupled to the first operator control assembly to selectively
support the first operator control assembly at a plurality of vertical positions relative
to the floorboard; and
a second operator control assembly, a second fixture structure coupled to the second
support structure to selectively support the second operator control assembly in a
plurality of angular orientations relative to the second support structure, and a
second vertical adjustment assembly coupled to the second operator control assembly
to selectively support the second operator control assembly at a plurality of vertical
positions relative to the floorboard.
H. The operator control system according to paragraph G, wherein:
the first fixture structure comprises a first mounting plate with one or more first
openings and one more second openings and a first plurality of fasteners that couple
a first housing of the first operator control assembly to the first support structure,
wherein:
the first operator control assembly is mounted at a first angular orientation relative
to the first support structure when the first plurality of fasteners are received
in the one or more first openings; and
the first operator control assembly is mounted a second angular orientation relative
to the first support structure when the first plurality of fasteners are received
in the one or more second openings, the second angular orientation being different
from the first angular orientation; and
the second fixture structure comprises a second mounting plate with one or more third
openings and one or more fourth openings and a second plurality of fasteners that
couple a second housing of the second operator control assembly to the second support
structure, wherein:
the second operator control assembly is mounted at a third angular orientation relative
to the second support structure when the second plurality of fasteners are received
in the one or more third openings; and
the second operator control assembly is mounted at a fourth angular orientation relative
to the second support structure when the second plurality of fasteners are received
in the one or more fourth openings, the fourth angular orientation being different
from the third angular orientation.
I. The operator control system according to paragraph H, wherein:
the first operator control assembly is rotated about a first axis generally parallel
to a longitudinal axis of the materials handling vehicle when moved from the first
angular orientation to the second angular orientation; and
the second operator control assembly is rotated in an opposite direction about a second
axis generally parallel to the longitudinal axis of the materials handling vehicle
when moved from the third angular orientation to the fourth angular orientation.
J. The operator control system according to any of paragraphs G to I, wherein:
the first support structure comprises a first fixed housing portion and a first movable
housing portion, the first movable housing portion being coupled to and movable with
the first operator control assembly, wherein the first movable housing portion is
positioned to telescope over the first fixed housing portion; and
the second support structure comprises a second fixed housing portion and a second
movable housing portion, the second movable housing portion being coupled to and movable
with the second operator control assembly, wherein the second movable housing portion
is positioned to telescope over the second fixed housing portion.
K. The operator control assembly according to any of paragraphs G to J, wherein:
the first operator control assembly is continuously movable in a vertical direction
between a first vertical position and a second vertical position; and
the second operator control assembly is continuously movable in a vertical direction
between a third vertical position and a fourth vertical position.
L. The operator control assembly according to any of paragraphs G to K, wherein at
least one of the angular orientation or the vertical position of the first operator
control assembly is adjustable independent of at least one of the angular orientation
or the vertical position of the second operator control assembly.
M. The operator control assembly according to any of paragraphs G to L, wherein:
the first vertical adjustment assembly comprises:
a first mounting plate attached to a support wall of the materials handling vehicle;
a first rail member attached to the first mounting plate;
a first carriage assembly movably coupled to the first rail member, wherein the first
carriage assembly is coupled to the first fixture structure; and
a first locking gas spring coupled to the first fixture structure and the first mounting
plate to control the vertical position of the first operator control assembly; and
the second vertical adjustment assembly comprises:
a second mounting plate attached to the support wall of the materials handling vehicle;
a second rail member attached to the second mounting plate;
a second carriage assembly movably coupled to the second rail member, wherein the
second carriage assembly is coupled to the second fixture structure; and
a second locking gas spring coupled to the second fixture structure and the second
mounting plate to control the vertical position of the second operator control assembly.
N. An operator control system for a materials handling vehicle, the materials handling
vehicle comprising an operator station having a generally horizontal floor surface
and a support structure, the operator control system comprising:
an operator control assembly comprising:
a housing mounted to the support structure; and
a steering assembly for steering the materials handling vehicle, the steering assembly
comprising a steering control structure and a base structure from which the steering
control structure extends, wherein the steering assembly is movable with respect to
the housing such that the steering assembly can be positioned in at least one of first
or second positions, wherein:
while in the first position, the steering control structure extends from the base
structure generally in a first orientation; and
while in the second position, the steering control structure extends from the base
structure generally in a second orientation different from the first orientation;
and
a vertical adjustment assembly coupled to the operator control assembly to selectively
support the operator control assembly at a plurality of vertical positions relative
to the generally horizontal floor surface.
O. The operator control system according to paragraph N, wherein the base structure
comprises a base plate and a mount coupled to the base plate, the mount being pivotably
mounted within a socket of the housing to enable the steering assembly to be moved
between the first and second positions.
P. The operator control system according to paragraph N or O, wherein:
when the steering assembly is positioned in the first position, the steering control
structure is oriented at an acute angle relative to a vertical plane, wherein the
vertical plane is perpendicular to the generally horizontal floor surface of the vehicle;
and
when the steering assembly is positioned in the second position, the steering control
structure is oriented at an acute angle relative to a horizontal plane, wherein the
horizontal plane is parallel to the generally horizontal floor surface of the vehicle.
Q. The operator control system according to any of paragraphs N to P, further comprising
a lock assembly for locking the steering assembly in the at least one of the first
or second positions, wherein the lock assembly comprises a lock release structure
for unlocking the lock assembly such that the steering assembly can be moved between
the at least one of the first or second positions.
R. The operator control system according to any of paragraphs N to Q, wherein the
steering assembly moves independently of the support structure and the housing, such
that the support structure and the housing remain in a same position when the steering
assembly is in the first position and the second position.
S. The operator control system according to paragraph R, wherein the housing further
comprises a control element area and wherein the steering assembly moves independently
of the control element area.
T. The operator control system according to according to any of paragraphs N to S,
wherein the support structure comprises a fixed housing portion and a movable housing
portion, the movable housing portion being coupled to and movable with the operator
control assembly, wherein the movable housing portion is positioned to telescope over
the fixed housing portion.
U. The operator control system according to any of paragraphs N to T, wherein the
operator control assembly is continuously movable in a vertical direction between
a first vertical position and a second vertical position.
V. The operator control system according to any of paragraphs N to U, wherein the
vertical adjustment assembly comprises:
a mounting plate attached to a support wall of the vehicle;
a rail member attached to the mounting plate;
a carriage assembly movably coupled to the rail member, wherein the carriage assembly
is coupled to the fixture structure; and
a locking gas spring coupled to the fixture structure and the mounting plate to control
the vertical position of the operator control assembly.
W. An operator control system for a materials handling vehicle, the materials handling
vehicle comprising an operator station having a generally horizontal floor surface,
a first support structure, and a second support structure spaced apart from the first
support structure in a lateral direction, the operator control system comprising:
a first operator control assembly comprising:
a first housing mounted to the first support structure; and
a steering assembly for steering the materials handling vehicle, the steering assembly
comprising a steering control structure and a base structure from which the steering
control structure extends, wherein the steering assembly is movable with respect to
the first housing such that the steering assembly can be positioned in at least one
of first or second positions, wherein:
while in the first position, the steering control structure extends from the base
structure generally in a first orientation; and
while in the second position, the steering control structure extends from the base
structure generally in a second orientation different from the first orientation;
and
a first vertical adjustment assembly coupled to the first operator control assembly
to selectively support the first operator control assembly at a plurality of vertical
positions relative to the generally horizontal floor surface; and
a second operator control assembly comprising a second housing mounted to the second
support structure; and
a second vertical adjustment assembly coupled to the second operator control assembly
to selectively support the second operator control assembly at a plurality of vertical
positions relative to the generally horizontal floor surface.
X. The operator control system according to paragraph W, wherein the base structure
comprises a base plate and a mount coupled to the base plate, wherein the mount being
pivotably mounted within a socket of the housing to enable the steering assembly to
be moved between the first and second positions.
Y. The operator control system according to paragraph W or X, wherein:
when the steering assembly is positioned in the first position, the steering control
structure is oriented at an acute angle relative to a vertical plane, wherein the
vertical plane is perpendicular to the generally horizontal floor surface of the vehicle;
and
when the steering assembly is positioned in the second position, the steering control
structure is oriented at an acute angle relative to a horizontal plane, wherein the
horizontal plane is parallel to the generally horizontal floor surface of the vehicle.
Z. The operator control system according to any of paragraphs W to Y, wherein the
steering assembly moves independently of the first support structure and the first
housing, such that the first support structure and the first housing remain in a same
position when the steering assembly is in the first position and the second position.
AA. The operator control system according to paragraph Z, wherein the first housing
further comprises a control element area and wherein the steering assembly moves independently
of the control element area.
BB. The operator control system according to any of paragraphs W to AA, wherein:
the first support structure comprises a first fixed housing portion and a first movable
housing portion, the first movable housing portion being coupled to and movable with
the first operator control assembly, wherein the first movable housing portion is
positioned to telescope over the first fixed housing portion; and
the second support structure comprises a second fixed housing portion and a second
movable housing portion, the second movable housing portion being coupled to and movable
with the second operator control assembly, wherein the second movable housing portion
is positioned to telescope over the second fixed housing portion.
CC. The operator control assembly according to any of paragraphs W to BB, wherein:
the first operator control assembly is continuously movable in a vertical direction
between a first vertical position and a second vertical position; and
the second operator control assembly is continuously movable in a vertical direction
between a third vertical position and a fourth vertical position.
DD. The operator control assembly according to any of paragraphs W to CC, wherein
the vertical position of the first operator control assembly is adjustable independent
of the vertical position of the second operator control assembly.
EE. The operator control assembly according to any of paragraphs W to DD, wherein
the vertical position of the second operator control assembly is adjustable independent
of at least one of the vertical position of the first operator control assembly or
positioning of the steering assembly.
FF. The operator control assembly according to any of paragraphs W to EE, wherein:
the first vertical adjustment assembly comprises:
a first mounting plate attached to a support wall of the materials handling vehicle;
a first rail member attached to the first mounting plate;
a first carriage assembly movably coupled to the first rail member, wherein the first
carriage assembly is coupled to the first fixture structure; and
a first locking gas spring coupled to the first fixture structure and the first mounting
plate to control the vertical position of the first operator control assembly; and
the second vertical adjustment assembly comprises:
a second mounting plate attached to the support wall of the materials handling vehicle;
a second rail member attached to the second mounting plate;
a second carriage assembly movably coupled to the second rail member, wherein the
second carriage assembly is coupled to the second fixture structure; and
a second locking gas spring coupled to the second fixture structure and the second
mounting plate to control the vertical position of the second operator control assembly.
GG. An operator control system for a materials handling vehicle, the materials handling
vehicle comprising an operator station having a support structure, the operator control
system comprising:
an operator control assembly comprising:
a housing mounted to the support structure, the housing comprising a recess;
a first elongate grip member mounted to the housing at at least one grip mount location
and extending over the recess; and
a first control element mounted to the housing within the recess, the first control
element configured to control a function of the materials handling vehicle; and
a vertical adjustment assembly coupled to the operator control assembly to selectively
support the operator control assembly at a plurality of vertical positions relative
to the floorboard,
wherein the first elongate grip member is replaceable with a second elongate grip
member mounted to the housing at the at least one grip mount location and extending
over the recess and having at least one of different dimensions or a different configuration
than the first grip member.
HH. The operator control system according to paragraph GG, wherein the at least one
grip mount location comprises first and second grip mount locations, the first grip
mount location being on a first side of the recess and the second grip mount location
being on a second side of the recess opposite to the first side of the recess.
II. The operator control system according to paragraph GG or HH, wherein the support
structure comprises a fixed housing portion and a movable housing portion, the movable
housing portion being coupled to and movable with the operator control assembly, wherein
the movable housing portion is positioned to telescope over the fixed housing portion.
JJ. The operator control system according to any of paragraphs GG to II, wherein the
operator control assembly is continuously movable in a vertical direction between
a first vertical position and a second vertical position.
KK. The operator control system according to any of paragraphs GG to JJ, wherein the
vertical adjustment assembly comprises:
a mounting plate attached to a support wall of the vehicle;
a rail member attached to the mounting plate;
a carriage assembly movably coupled to the rail member, wherein the carriage assembly
is coupled to the fixture structure; and
a locking gas spring coupled to the fixture structure and the mounting plate to control
the vertical position of the operator control assembly.
LL. An operator control system for a materials handling vehicle, the materials handling
vehicle comprising an operator station having a support structure, the operator control
system comprising:
an operator control assembly comprising:
a housing mounted to the support structure, the housing comprising a recess;
a first elongate grip member mounted to the housing and extending over the recess;
and
a first control element mounted to the housing within the recess, the first control
element configured to control a function of the materials handling vehicle and positionable
in a plurality of positions comprising two end positions; and
wherein at least one of:
the first elongate grip member is replaceable with a second elongate grip member extending
over the recess and having at least one of different dimensions or a different configuration
than the first grip member; or
the first control element is replaceable with a second control element, the second
control element being positionable in a plurality of positions comprising two end
positions and having at least one of different dimensions or a different configuration
than the first control element;
wherein a gap between adjacent portions of one of the first or the second control
element and one of the first or the second grip member falls within a range of from
a minimum clearance distance to a maximum reach distance with the first or the second
control element positioned in any one of its plurality of positions; and
a vertical adjustment assembly coupled to the operator control assembly to selectively
support the operator control assembly at a plurality of vertical positions relative
to the floorboard.
MM. The operator control system according to paragraph LL, wherein the first elongate
grip member is secured to the housing at first and second grip mount locations, with
the first grip mount location being on a first side of the recess and the second grip
mount location being on a second side of the recess opposite to the first side of
the recess.
NN. An operator control system for a materials handling vehicle, the materials handling
vehicle comprising an operator station having a floorboard and a support structure,
the operator control system comprising:
an operator control assembly comprising:
a housing mounted to the support structure;
a vertical adjustment assembly coupled to the operator control assembly to selectively
support the operator control assembly at a plurality of vertical positions relative
to the floorboard; and
at least one of:
a steering assembly for steering the materials handling vehicle, the steering assembly
comprising a steering control structure and a base structure from which the steering
control structure extends, wherein the steering assembly is movable with respect to
the housing such that the steering assembly can be positioned in at least one of first
or second positions, wherein the steering control structure extends from the base
structure generally in a first orientation while in the first position, and wherein
the steering control structure extends from the base structure generally in a second
orientation while in the second position, the second orientation being different from
the first orientation; or
a fixture structure coupled to the support structure to selectively support the operator
control assembly in a plurality of angular orientations relative to the support structure.
OO. An operator control system for a materials handling vehicle, the materials handling
vehicle comprising an operator station having a floorboard and a support structure,
the operator control system comprising:
an operator control assembly comprising:
a housing mounted to the support structure, the housing comprising a recess;
a vertical adjustment assembly coupled to the operator control assembly to selectively
support the operator control assembly at a plurality of vertical positions relative
to the floorboard; and
at least one of:
a first control element mounted to the housing within the recess and a first elongate
grip member mounted to the housing at at least one grip mount location and extending
over the recess, wherein the first elongate grip member is replaceable with a second
elongate grip member having at least one of different dimensions or a different configuration
than the first grip member, and wherein the first control element is replaceable with
a second control element that is positionable in a plurality of positions comprising
two end positions and having at least one of different dimensions or a different configuration
than the first control element; or
a fixture structure coupled to the support structure to selectively support the operator
control assembly in a plurality of angular orientations relative to the support structure.
PP. An operator control system for a materials handling vehicle, the materials handling
vehicle comprising an operator station having a floorboard, a first support structure,
and a second support structure spaced apart from the first support structure in a
lateral direction, the operator control system comprising:
a first operator control assembly comprising:
a first housing mounted to the first support structure;
a first vertical adjustment assembly coupled to the first operator control assembly
to selectively support the first operator control assembly at a plurality of vertical
positions relative to the floorboard; and
at least one of:
a steering assembly for steering the materials handling vehicle, the steering assembly
comprising a steering control structure and a base structure from which the steering
control structure extends, wherein the steering assembly is movable with respect to
the housing such that the steering assembly can be positioned in at least one of first
or second positions, wherein the steering control structure extends from the base
structure generally in a first orientation while in the first position, and wherein
the steering control structure extends from the base structure generally in a second
orientation while in the second position, the second orientation being different from
the first orientation; or
a first fixture structure coupled to the first support structure to selectively support
the first operator control assembly in a plurality of angular orientations relative
to the first support structure; and
a second operator control assembly comprising:
a second housing mounted to the second support structure, the second housing comprising
a recess;
a second vertical adjustment assembly coupled to the second operator control assembly
to selectively support the second operator control assembly at a plurality of vertical
positions relative to the floorboard; and
at least one of:
a first control element mounted to the housing within the recess and a first elongate
grip member mounted to the housing at at least one grip mount location and extending
over the recess, wherein the first elongate grip member is replaceable with a second
elongate grip member having at least one of different dimensions or a different configuration
than the first grip member, and wherein the first control element is replaceable with
a second control element that is positionable in a plurality of positions comprising
two end positions and having at least one of different dimensions or a different configuration
than the first control element; or
a second fixture structure coupled to the second support structure to selectively
support the second operator control assembly in a plurality of angular orientations
relative to the second support structure.
QQ. An operator control system for a materials handling vehicle, the materials handling
vehicle including an operator station having a first support structure, the operator
control system comprising:
a first operator control assembly comprising:
a first housing mounted to or integral with the first support structure; and
a steering assembly for steering the materials handling vehicle, the steering assembly
comprising a steering control structure and a base structure from which the steering
control structure extends, wherein the steering assembly is movable with respect to
the first housing such that the steering assembly can be positioned in at least one
of first or second positions, wherein:
while in the first position, the steering control structure extends from the base
structure generally in a first orientation; and
while in the second position, the steering control structure extends from the base
structure generally in a second orientation different from the first orientation.
RR. The operator control system according to paragraph QQ, wherein the base structure
comprises a base plate and a mount coupled to the base plate.
SS. The operator control system according to paragraph RR, wherein the mount is received
in a socket of the first housing.
TT. The operator control system according to paragraph SS, wherein the mount is pivotably
mounted within the first housing socket to enable the steering assembly to be moved
between the first and second positions.
UU. The operator control system according to paragraph S or paragraph TT, wherein
the mount has a semi-spherical shape and the socket has a corresponding semi-spherical
shape.
VV. The operator control system according to any of paragraphs RR to UU, wherein the
base plate is rotatably mounted on the mount such that the base plate is rotatable
with respect to the mount.
WW. The operator control system according to any of paragraphs RR to VV, wherein the
steering control structure is rotatably mounted on the base plate such that the steering
control structure is rotatable with respect to the base plate.
XX. The operator control system according to any of paragraphs RR to WW, wherein the
base plate includes a plurality of indentations around a periphery of the base plate.
YY. The operator control system according to any of paragraphs RR to XX, wherein,
when the steering assembly is positioned in the first position, the steering control
structure is oriented at an acute angle relative to a vertical plane, wherein the
vertical plane is perpendicular to a generally horizontal floor surface of the vehicle.
ZZ. The operator control system according to claim any of paragraphs RR to YY, wherein,
when the steering assembly is positioned in the second position, the steering control
structure is oriented at an acute angle relative to a horizontal plane, wherein the
horizontal plane is parallel to the generally horizontal floor surface of the vehicle.
AAA. The operator control system according to any of paragraphs RR to ZZ, further
comprising a lock assembly for locking the steering assembly in the at least one of
the first or second positions.
BBB. The operator control system according to paragraph AAA, wherein the lock assembly
comprises a lock release structure for unlocking the lock assembly such that the steering
assembly can be moved between the at least one of the first or second positions.
CCC. The operator control system according to paragraph AAA or paragraph BBB, wherein
the lock assembly comprises a sensor for sensing the steering assembly in the at least
one of the first or second positions.
DDD. The operator control system according to any of paragraphs RR to CCC, further
comprising fixture structure coupled to the first support structure to selectively
support the first operator control assembly in different positions on the first support
structure.
EEE. The operator control system according to paragraph DDD, wherein the fixture structure
comprises a mounting plate coupled to the first support structure and a plurality
of fasteners that extend through openings provided in the mounting plate, and wherein
the fasteners couple the first housing to the first support structure.
FFF. The operator control system according to paragraph EEE, wherein the mounting
plate comprises one or more first openings and one more second openings, wherein the
first operator control assembly is mounted at a first orientation relative to the
first support structure when the fasteners are received in the one or more first openings
of the mounting plate and the first operator control assembly is mounted at a second
orientation different from the first orientation relative to the first support structure
when the fasteners are received in the one or more second openings.
GGG. The operator control system according to claim any of paragraphs RR to FFF, wherein
the first housing has a curved lower surface that is received by a curved upper surface
of the first support structure.
HHH. The operator control system according to any of paragraphs RR to GGG, further
comprising:
a second operator control assembly comprising:
a second housing mounted to second support structure of the materials handling vehicle;
and
at least one control element associated with the second housing for controlling a
function of the materials handling vehicle;
wherein the first and second support structures of the materials handling vehicle
are spaced apart from one another in a lateral direction of the materials handling
vehicle, the lateral direction being perpendicular to a longitudinal axis of the materials
handling vehicle.
III. The operator control system according to paragraph HHH, wherein the first and
second support structures of the materials handling vehicle are separated by a recessed
portion of the materials handling vehicle that defines an open area extending downward
from the first and second operator control assemblies toward a floor surface.
JJJ. The operator control system according to any of paragraphs RR to III, wherein
the operator station is located in an operator compartment having a floor surface
on which the operator stands while operating the vehicle using the operator control
system.
KKK. An operator control system for a materials handling vehicle, the materials handling
vehicle including an operator station having a first support structure, the operator
control system comprising:
a first operator control assembly; and
fixture structure coupled to the first support structure to selectively support the
first operator control assembly in different positions on the first support structure.
LLL. The operator control system according to paragraph KKK, wherein the fixture structure
comprises a mounting plate coupled to the first support structure and a plurality
of fasteners that extend through openings provided in the mounting plate, and wherein
the fasteners couple a first housing of the first operator control assembly to the
first support structure.
MMM. The operator control system according to paragraph LLL, wherein the mounting
plate comprises one or more first openings and one more second openings, wherein the
first operator control assembly is mounted at a first orientation relative to the
first support structure when the fasteners are received in the one or more first openings
of the mounting plate and the first operator control assembly is mounted at a second
orientation different from the first orientation relative to the first support structure
when the fasteners are received in the one or more second openings.
NNN. The operator control system according to paragraph LLL, wherein the mounting
plate comprises one or more first openings and one more second openings, wherein the
first operator control assembly is positioned at a first angular orientation relative
to the first support structure when the fasteners are received in the one or more
first openings of the mounting plate and the first operator control assembly is rotated
about an axis generally parallel to a longitudinal axis of the materials handling
vehicle when moved from the first angular orientation to a second angular orientation
such that the first operator control assembly is mounted in the second angular orientation
when the fasteners are received in the one or more second openings.
OOO. The operator control system according to any of paragraphs KKK to NNN, wherein
the first housing has a curved lower surface that is received by a curved upper surface
of the first support structure.
PPP. The operator control system according to any of paragraphs KKK to OOO, further
comprising:
a second operator control assembly mounted to second support structure of the materials
handling vehicle;
wherein the first and second support structures of the materials handling vehicle
are spaced apart from one another in a lateral direction of the materials handling
vehicle, the lateral direction being perpendicular to a longitudinal axis of the materials
handling vehicle.
QQQ. The operator control system according to any of paragraphs KKK to PPP, wherein
the fixture structure selectively supports the first operator control assembly in
different angular orientations relative to the first support structure.
RRR. An operator control system for a materials handling vehicle, the materials handling
vehicle including an operator station having a support structure, the operator control
system comprising:
an operator control assembly comprising:
a housing mounted to or integral with the support structure, the housing including
a recess;
a first elongate grip member mounted to the housing and extending over the housing
recess; and
a first control element mounted to the housing within the recess, the first control
element configured to control a function of the materials handling vehicle and positionable
in a plurality of positions including two end positions; and
wherein at least one of:
the first elongate grip member is replaceable with a second elongate grip member extending
over the housing recess and having at least one of different dimensions or a different
configuration than the first grip member; or
the first control element is replaceable with a second control element, the second
control element being positionable in a plurality of positions including two end positions
and having at least one of different dimensions or a different configuration than
the first control element;
wherein a gap between adjacent portions of one of the first or the second control
element and one of the first or the second grip member falls within a range of from
a minimum clearance distance to a maximum reach distance with the first or the second
control element positioned in any one of its plurality of positions.
SSS. The operator control system according to paragraph RRR, wherein the housing recess
has a curvilinear shape.
TTT. The operator control system according to paragraph RRR or paragraph SSS, wherein
the first control element is a switch or lever.
UUU. The operator control system according to any of paragraphs KKK to TTT, wherein
the first elongate grip member is secured to the housing at first and second grip
mount locations, with the first grip mount location being on a first side of the housing
recess and the second grip mount location being on a second side of the housing recess
opposite to the first side of the housing recess.
VVV. The operator control system according to any of paragraphs KKK to UUU, wherein
the first elongate grip member includes a third control element.
WWW. An operator control system for a materials handling vehicle, the materials handling
vehicle including an operator station having a support structure, the operator control
system comprising:
an operator control assembly comprising:
a housing mounted to or integral with the support structure, the housing including
a recess;
a first elongate grip member mounted to the housing at at least one grip mount location
and extending over the housing recess; and
a first control element mounted to the housing within the recess, the first control
element configured to control a function of the materials handling vehicle; and
wherein the first elongate grip member is replaceable with a second elongate grip
member mounted to the housing at the at least one grip mount location and extending
over the housing recess and having at least one of different dimensions or a different
configuration than the first grip member.
XXX. The operator control system according to paragraph WWW, wherein the housing recess
has a curvilinear shape.
YYY. The operator control system according to paragraph WWW or paragraph XXX, wherein
the first control element is a switch or lever.
ZZZ. The operator control system according to any of paragraphs WWW to YYY, wherein
the at least one grip mount location comprises first and second grip mount locations,
the first grip mount location being on a first side of the housing recess and the
second grip mount location being on a second side of the housing recess opposite to
the first side of the housing recess.
AAAA. The operator control system according to any of paragraphs WWW to ZZZ, wherein
the first elongate grip member includes a second control element.
[0152] The various features, aspects, and embodiments described herein can be used in any
combination(s) with one another, or on their own.
[0153] Having thus described embodiments in detail, it will be apparent that modifications
and variations are possible without departing from the scope of the appended claims.
Clauses:
[0154] Alternative expressions of the inventive concept are set out in the following clauses.
- 1. An operator control system for a materials handling vehicle, the materials handling
vehicle including an operator station having a support structure, the operator control
system comprising:
an operator control assembly comprising:
a housing mounted to or integral with the support structure, the housing including
a recess;
a first elongate grip member mounted to the housing and extending over the housing
recess; and
a first control element mounted to the housing within the recess, the first control
element configured to control a function of the materials handling vehicle and positionable
in a plurality of positions including two end positions; and
wherein at least one of:
the first elongate grip member is replaceable with a second elongate grip member extending
over the housing recess and having at least one of different dimensions or a different
configuration than the first grip member; or
the first control element is replaceable with a second control element, the second
control element being positionable in a plurality of positions including two end positions
and having at least one of different dimensions or a different configuration than
the first control element;
wherein a gap between adjacent portions of one of the first or the second control
element and one of the first or the second grip member falls within a range of from
a minimum clearance distance to a maximum reach distance with the first or the second
control element positioned in any one of its plurality of positions.
- 2. The operator control system according to clause 1, wherein the housing recess has
a curvilinear shape.
- 3. The operator control system according to clause 1 or clause 2, wherein the first
control element is a switch or lever.
- 4. The operator control system according to any of clauses 1-3, wherein the first
elongate grip member is secured to the housing at first and second grip mount locations,
with the first grip mount location being on a first side of the housing recess and
the second grip mount location being on a second side of the housing recess opposite
to the first side of the housing recess.
- 5. The operator control system according to any of clauses 1-4, wherein the first
elongate grip member includes a third control element configured to control a function
of the materials handling vehicle.
- 6. An operator control system for a materials handling vehicle, the materials handling
vehicle including an operator station having a support structure, the operator control
system comprising:
an operator control assembly comprising:
a housing mounted to or integral with the support structure, the housing including
a recess;
a first elongate grip member mounted to the housing at at least one grip mount location
and extending over the housing recess; and
a first control element mounted to the housing within the recess, the first control
element configured to control a function of the materials handling vehicle; and
wherein the first elongate grip member is replaceable with a second elongate grip
member mounted to the housing at the at least one grip mount location and extending
over the housing recess and having at least one of different dimensions or a different
configuration than the first grip member.
- 7. The operator control system according to clause 6, wherein the housing recess has
a curvilinear shape.
- 8. An operator control system for a materials handling vehicle, the materials handling
vehicle including an operator station having a first support structure, the operator
control system comprising:
a first operator control assembly comprising:
a first housing mounted to or integral with the first support structure, the first
housing comprising a socket; and
a steering assembly for steering the materials handling vehicle, the steering assembly
comprising a steering control structure and a base structure from which the steering
control structure extends, wherein the base structure comprises a base plate and a
mount coupled to the base plate, the mount being pivotably mounted within the socket
of the first housing such that the steering assembly is movable between at least a
first position and a second position, wherein:
when in the first position, the steering control structure extends from the base structure
generally in a first orientation; and
when in the second position, the steering control structure extends from the base
structure generally in a second orientation different from the first orientation.
- 9. The operator control system according to clause 8, wherein:
the first housing further comprises a control element area; and
the steering assembly moves independently of the control element area.
- 10. The operator control system according to clause 9, wherein an orientation of the
control element area with respect to the first support structure remains unchanged
regardless of whether the steering control assembly is in the first position or the
second position.
- 11. The operator control system according to any of clauses 8-10, wherein the mount
has a semi-spherical shape and the socket has a corresponding semi-spherical shape.
- 12. The operator control system according to any of clauses 8-11, wherein the base
plate includes a plurality of indentations around a periphery of the base plate.
- 13. The operator control system according to any of clauses 8-12, wherein:
when the steering assembly is positioned in the first position, the steering control
structure is oriented at an acute angle relative to a vertical plane, wherein the
vertical plane is perpendicular to a generally horizontal floor surface of the vehicle;
and
when the steering assembly is positioned in the second position, the steering control
structure is oriented at an acute angle relative to a horizontal plane, wherein the
horizontal plane is parallel to the generally horizontal floor surface of the vehicle.
- 14. The operator control system according to any of clauses 8-13, further comprising
a lock assembly for locking the steering assembly in the at least one of the first
or second positions, wherein the lock assembly comprises a lock release structure
for unlocking the lock assembly such that the steering assembly can be moved between
the at least one of the first or second positions.
- 15. An operator control system for a materials handling vehicle, the materials handling
vehicle including an operator station having a first support structure and a second
support structure, wherein the first and second support structures are spaced apart
from one another in a lateral direction of the materials handling vehicle, the lateral
direction being perpendicular to a longitudinal axis of the materials handling vehicle,
the operator control system comprising:
a first operator control assembly supported on the first support structure via a first
fixture structure that selectively supports the first operator control assembly in
one of at least first and second angular orientations relative to the first support
structure; and
a second operator control assembly supported on the second support structure via a
second fixture structure that selectively supports the second operator control assembly
in one of at least first and second angular orientations relative to the second support
structure;
wherein positioning of the first and second operator control assemblies in the respective
first or second angular orientation is dependent upon a spacing of the first support
structure relative to the second support structure in the lateral direction.
- 16. The operator control system according to clause 15, wherein the first and second
fixture structures each comprise a mounting plate coupled to the respective first
or second support structure and a plurality of fasteners that extend through openings
provided in the mounting plate, and wherein the fasteners couple respective first
and second housings of the first and second operator control assemblies to the corresponding
support structures.
- 17. The operator control system according to clause 15 or clause 16, wherein each
mounting plate comprises one or more first openings and one more second openings,
and wherein:
the first operator control assembly is positioned at the first angular orientation
relative to the first support structure when the fasteners are received in the one
or more first openings of the mounting plate of the first fixture structure and the
first operator control assembly is rotated about a first axis generally parallel to
a longitudinal axis of the materials handling vehicle when moved from the first angular
orientation to the second angular orientation such that the first operator control
assembly is mounted in the second angular orientation when the fasteners are received
in the one or more second openings; and
the second operator control assembly is positioned at the first angular orientation
relative to the second support structure when the fasteners are received in the one
or more first openings of the mounting plate of the second fixture structure and the
second operator control assembly is rotated about a second axis generally parallel
to a longitudinal axis of the materials handling vehicle when moved from the first
angular orientation to the second angular orientation such that the second operator
control assembly is mounted in the second angular orientation when the fasteners are
received in the one or more second openings.
- 18. The operator control system according to any of clauses 15-17, wherein the first
housing has a curved lower surface that is received by a curved upper surface of the
first support structure and the second housing has a curved lower surface that is
received by a curved upper surface of the second support structure.
- 19. The operator control system according to any of clauses 15-18, wherein for a narrower
width vehicle, the first and second operator control assemblies are positioned in
the first angular orientation, and for a wider width vehicle, the first and second
operator control assemblies are positioned in the second angular orientation.
- 20. An operator control system for a materials handling vehicle, the materials handling
vehicle comprising an operator station having a generally horizontal floor surface
and a support structure, the operator control system comprising:
an operator control assembly supported by the support structure;
a vertical adjustment assembly coupled to the operator control assembly to selectively
support the operator control assembly at a plurality of vertical positions on the
support structure relative to the generally horizontal floor surface; and
at least one of:
- A) a housing mounted to the support structure; and
a steering assembly for steering the materials handling vehicle, the steering assembly
comprising a steering control structure and a base structure from which the steering
control structure extends, wherein the steering assembly is movable with respect to
the housing such that the steering assembly can be positioned in at least one of first
or second positions, wherein:
while in the first position, the steering control structure extends from the base
structure generally in a first orientation; and
while in the second position, the steering control structure extends from the base
structure generally in a second orientation different from the first orientation;
- B) a fixture structure coupled to the support structure to selectively support the
operator control assembly in a plurality of angular orientations relative to the support
structure; or
- C) a housing mounted to the support structure, the housing comprising a recess;
a first elongate grip member mounted to the housing at at least one grip mount location
and extending over the recess; and
a first control element mounted to the housing within the recess, the first control
element configured to control a function of the materials handling vehicle; and
wherein the first elongate grip member is replaceable with a second elongate grip
member mounted to the housing at the at least one grip mount location and extending
over the recess and having at least one of different dimensions or a different configuration
than the first grip member.